Turbine Inspection and Modeling Analysis of Locking Pins in the Penultimate-Stage Blades of a 600 MW Steam Turbine

The fracture behavior of a locking pin used in the penultimate-stage blades of a 600 MW steam turbine in a thermal power plant was investigated through microstructural and microhardness characterization, fracture surface and energy-dispersive spectroscopy (EDS) analysis, as well as finite element load simulation. The microhardness values measured on the cross-section of the service pins ranged from 528 to 541 HV0.1, showing little difference from the unused pins. Scanning electron microscopy analysis revealed that approximately 70% of the fracture surfaces exhibited an intergranular “rock candy” morphology. The results indicate that pin failure was primarily caused by the combined effects of fretting wear and stress corrosion cracking (SCC). Specifically, vibration at the blade root, impeller, and pins due to start–stop cycles and load variations led to fretting wear, forming pits approximately 75 μm in size. Under the combined effects of weakly corrosive wet steam environments and shear stresses, SCC initiated at the high stress concentration points of these pits. Early crack propagation primarily followed original austenite grain boundaries, while later stages mainly extended along martensite plate boundaries. As cracks advanced, the cross-sectional area gradually decreased, causing the effective shear stress to increase until it exceeded the shear strength, ultimately leading to fracture. These findings not only provide a scientific basis for enhancing the reliability of steam turbine locking pins and extending their service life, but also contribute to a broader understanding of the failure mechanisms of key components operating under corrosive and fluctuating load environments.