Failure analysis of large and complex engine blades based on experimental research

Abstract On a certain day in December 2022, a GE90 engine equipped by an airline experienced a surge during flight. Ground inspection revealed broken blades of the 9-stage high-pressure compressor. To identify the cause of its fracture failure, the macroscopic fracture surface was first analyzed. Obvious fatigue crack propagation characteristics were found at the blade cross-section. Small pits formed by the impact were observed at the crack source location, indicating that the blade was first formed into a circular arc-shaped impact wound after being impacted by an external object. In the subsequent service process, under continuous vibration, fatigue cracks are formed at the impact point as the crack source and gradually propagate, ultimately leading to blade fracture and failure. To further explore the source of foreign objects causing impact damage, the surface scanning method using energy spectrum analysis was used. An enriched region of C element was found near the impact point. However, due to the lack of conditions for the formation of C combustion products at the compressor location, it can be considered that the foreign object may have come from external sources.