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Pack aluminization of low-pressure turbine blade of an aero gas turbine engine has been carried out following a well-defined systematic procedure. The process parameters are first optimized on dummy blades, and optimized process is followed for the actual blades for evaluation and testing. Visual and binocular examination followed by metallurgical evaluation has been carried out to validate the process and to establish the adequacy and correctness of the coating. The coated blades are then evaluated through component-level test and engine-level test followed by field evaluation trials for performance and durability. The results of engine-level tests and inspection post-accelerated mission test cycles ensure that the blades with aluminide coating can withstand severe engine operating cycles without any damage or failure which otherwise would have experienced. The failure-free operation for an equivalent TBO life and post-AMT condition of blades are an indication of enhanced life of aluminide blades and prevention of failure of the turbine blades through pack aluminization.
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