Remaining Useful Life Prediction Method for High Temperature Blades of Gas Turbines Based on 3D Reconstruction and Machine Learning Techniques

Turbine blades are crucial components exposed to harsh conditions, such as high temperatures, high pressures, and high rotational speeds. It is of great significance to accurately predict the life of blades for reducing maintenance cost and improving the reliability of gas turbine systems. A rapid and accurate blade life assessment method holds significant importance in the maintenance plan of gas turbine engines. In this paper, a novel on-line remaining useful life (RUL) prediction method for high-temperature blades is proposed based on 3D reconstruction technology and data-driven surrogate mode. Firstly, the 3D reconstruction technology was employed to establish the geometric model of real turbine blades, and the fluid–thermal–solid analysis under actual operational conditions was carried out in ANSYS software. Six checkpoints were selected to estimate the RUL according to the stress–strain distribution of the blade surface. The maximum equivalent stress was 1481.51 MPa and the highest temperature was 1393.42 K. Moreover, the fatigue-creep lifetime was calculated according to the parameters of the selected checkpoints. The RUL error between the simulation model and commercial software (Control and Engine Health Management (CEHM)) was less than 0.986%. Secondly, different data-driven surrogate models (BP, DNN, and LSTM algorithms) were developed according to the results from numerical simulation. The maximum relative errors of BP, DNN, and LSTM models were 0.030%, 0.019%, and 0.014%. LSTM demonstrated the best performance in predicting the RUL of turbine blades with time-series characteristics. Finally, the LSTM model was utilized for predicting the RUL within a gas turbine real operational process that involved five start–stop cycles.