Gas Turbine Blade Repair: Extend Life with Liburdi’s FSR® Process
Liburdi Turbines Services developed the patented Full Solution Rejuvenation® (FSR®) process to restore gas turbine blades to like-new strength and extend service life well beyond typical OEM limits.
Why Gas Turbine Blades Degrade Over Time
Gas turbine blades operate under extreme temperature and stress. Over time, thermal aging and creep cause overaging of the γ′ precipitate structure, reducing rupture strength and pushing components below safe performance levels. Under standard practices many blades are removed after two cycles due to microstructural degradation (see Figure 1).
Figure 1: Progressive loss of gas turbine blade creep strength with service time.
What Is FSR® and How Does It Work?
FSR® reverses microstructural degradation to restore alloy strength and extend the life of high-value blades.
There are two main phases:
Hot Isostatic Pressing (HIP):
Collapses internal creep voids in the alloy, re-densifying the blade’s microstructure.
Advanced Heat Treatments:
Dissolves overaged γ′ and regrows precipitates to optimal size, recovering creep strength and ductility.
Figures 2 and 3 illustrate recovery of microstructure and properties at the microscopic level.
Figure 2: FSR® reverses thermal aging damage in superalloys.
Figure 3: FSR® reverses stress damage in superalloys.
Rejuvenating Superalloys and Preventing Replacement
Microscopic voids and γ′ overaging drive strength loss. Applying FSR® at regular intervals restores creep strength, extends turbine blade life, and defers costly replacements. Figure 4 highlights the long-term benefit of FSR® compared to untreated components.
Figure 4: Turbine blade rejuvenated creep strength with service time
Where FSR® Applies (Alloys and Components)
- Cast and directionally solidified blades/buckets: Broadly proven
- Single-crystal alloys: Applicable with careful process control to avoid recrystallization; minimize cold work and verify via metallography.
- Coatings: External and internal coatings are stripped before FSR® and reapplied after heat treatment.
- Dimensional control: Minor stress-relief distortion is managed by repair sequencing, weld restoration, and finish machining.
Quality Assurance and Requalification
Each program is controlled and validated through:
- Stress-rupture testing on representative material from the production set.
- Microstructural verification of precipitate and grain-boundary condition.
- Tight control of time, temperature, and pressure for HIP and heat treatments.
Operator Value: Why Choose FSR® for Gas Turbine Blade Repair
- Extend blade service life beyond typical cycle limits
- Restore superalloy strength and microstructure for reliable return to service
- Reduce replacement spend and avoid long lead times
- Maintain engine performance and availability
- Improve sustainability by reducing scrap and material waste
Applied proactively, FSR® can save operators hundreds of thousands of dollars across the life of a set.
Ready to Maximize Blade Life?
Planning a gas turbine blade repair or evaluating life-extension options? Our team can review alloy, run conditions, and inspection data to recommend an FSR® schedule.
Contact: info@liburditurbineservices.com
