Inefficient combustion due to altered airflow can lead to increased emissions of pollutants.

Many modern gas turbine blades are protected by thermal barrier coatings (TBCs). However, these coatings themselves can crack, exposing the base metal to environmental attack. Research has shown that where the coating is cracked, environmental attack of the interdiffusion zone and base metal occurs, resulting in spallation of the coating and preferential grain boundary attack. Once the coating fails, the underlying superalloy becomes vulnerable to rapid oxidation and crack propagation.

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Nickel-based superalloys used in gas turbine hot gas path components often have limited weldability due to their highly alloyed nature. In some cases, liquation cracking, solidification, and strain age cracking can make these alloys practically unweldable. Particular concerns include high susceptibility to hot cracking during welding and post-weld heat treating.

High rotational speeds and the resultant centrifugal forces can cause mechanical stress, potentially leading to crack initiation and propagation.

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