scholarly journals Comparative Energy, Resource and Recycling Lifecycle Analysis of the Industrial Repair Process of Gas Turbine Burners Using Conventional Machining and Additive Manufacturing

2017 ◽  
Vol 21 (S1) ◽  
pp. S203-S215 ◽  
Author(s):  
Frank Walachowicz ◽  
Ingo Bernsdorf ◽  
Ulrike Papenfuss ◽  
Christine Zeller ◽  
Andreas Graichen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbine ◽  
Energy Resource ◽  
Repair Process ◽  
Lifecycle Analysis ◽  
Conventional Machining

An Assessment on the Benefits of Additive Manufacturing Regarding New Swirler Geometries for Gas Turbine Burners

2018 ◽  
Author(s):  
Fabrice Giuliani ◽  
Nina Paulitsch ◽  
Daniele Cozzi ◽  
Michael Görtler ◽  
Lukas Andracher
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbine ◽  
Inconel 718 ◽  
Advanced Materials ◽  
Gas Turbine Combustor ◽  
Engineering Research ◽  
Know How ◽  
Current State ◽  
Research And Education ◽  
Near Future

In the near future, combustion engineers will shape the burner according to the flame, and not the opposite way anymore. In this contribution, this idea is explored with the help of additive manufacturing (AM). The focus is put on the design and the production of swirlers using advanced materials with the least possible efforts in terms of manufacturing. The material chosen for this study is Inconel 718. There are three motivations to this project. The first one is to design new shapes and assess these in comparison to conventional ones. The second motivation is to be able to manufacture them using additive manufacturing, and to gather know-how on selective laser melting. The third motivation is to elaborate a methodology involving engineering, research and education to promote — only if and when this is desirable — the production of series of premium parts such as high-end components of gas turbine combustor using AM. First-of-a-kind swirler shapes are explained and designed. These are unlikely to be produced using conventional manufacturing. They are then successfully produced in Inconel 718 using AM. The raw parts are directly submitted for testing with no surface post-processing. The paper states why at current state-of-the-art the raw surface quality still needs improvement, and highlights the benefits of the new swirler shape versus conventional.

Development of a Dual-Fuel Gas Turbine Engine of Liquid and Low-Calorific Gas

2005 ◽  
Author(s):  
Masamichi Koyama ◽  
Hiroshi Fujiwara
Keyword(s):  
Gas Turbine ◽  
Sewage Treatment ◽  
Energy Resource ◽  
Biomass Energy ◽  
Dual Fuel ◽  
Fuel Gas ◽  
Turbine Engine ◽  
Reference Velocity ◽  
Continuous Use ◽  
Wasted Energy

We developed a dual-fuel single can combustor for the Niigata Gas Turbine (NGT2BC), which was developed as a continuous-duty gas turbine capable of burning both kerosene and digester gas. The output of the NGT2BC is 920 kW for continuous use with digester gas and 1375 kW for emergency use with liquid fuel. Digester gas, obtained from sludge processing at sewage treatment plants, is a biomass energy resource whose use reduces CO2 emissions and take advantage of an otherwise wasted energy source. Design features for good combustion with digester gas include optimized the good matching of gas injection and swirl air and reduced reference velocity. The optimal combination of these parameters was determined through CFD analysis and atmospheric rig testing.

Latest Gas Turbine Repair Techniques Using Laser Technology

1998 ◽  
Author(s):  
A.D. Williams ◽  
J.L. Humphries
Keyword(s):  
Gas Turbine ◽  
Repair Process ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Directionally Solidified ◽  
Laser Technology ◽  
Higher Power ◽  
Recent Developments ◽  
The Cost ◽  
Repair Techniques

Abstract Over recent years, with the drive for new higher power, higher efficiency Gas Turbine engines, manufacturers have had to look at new alloys and new coating techniques to achieve and support the industry requirements. Repair technology has therefore had to keep pace with the OEM advances and much research and development has been undertaken in developing new repair processes. Many of the alloys now used are directionally solidified or single crystal, which until now have been deemed irreparable by traditional welding techniques. Recent developments in the use of lasers have not only rendered these alloys salvageable but have also reduced the overall repair time and therefore the cost. This paper looks at the use of laser technology as a repair process for gas turbine components, touching briefly on laser cutting and drilling but concentrating mainly on laser powder feed welding and its applications.

Topology Optimization of Serpentine Channels for Minimization of Pressure Loss and Maximization of Heat Transfer Performance As Applied for Additive Manufacturing

2019 ◽  
Author(s):  
Shinjan Ghosh ◽  
Jayanta S. Kapat
Keyword(s):  
Heat Transfer ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Pressure Drop ◽  
Gas Turbine ◽  
Turbine Blades ◽  
Inlet Temperature ◽  
Internal Cooling ◽  
Cooling Channels ◽  
Blade Cooling

Abstract Gas Turbine blade cooling is an important topic of research, as a high turbine inlet temperature (TIT) essentially means an increase in efficiency of gas turbine cycles. Internal cooling channels in gas turbine blades are key to the cooling and prevention of thermal failure of the material. Serpentine channels are a common feature in internal blade cooling. Optimization methods are often employed in the design of blade internal cooling channels to improve heat-transfer and reduce pressure drop. Topology optimization uses a variable porosity approach to manipulate flow geometries by adding or removing material. Such a method has been employed in the current work to modify the geometric configuration of a serpentine channel to improve total heat transferred and reduce the pressure drop. An in-house OpenFOAM solver has been used to create non-traditional geometries from two generic designs. Geometry-1 is a 2-D serpentine passage with an inlet and 4 bleeding holes as outlets for ejection into the trailing edge. Geometry-2 is a 3-D serpentine passage with an aspect ratio of 3:1 and consists of two 180-degree bends. The inlet velocity for both the geometries was used as 20 m/s. The governing equations employ a “Brinkman porosity parameter” to account for the porous cells in the flow domain. Results have shown a change in shape of the channel walls to enhance heat-transfer in the passage. Additive manufacturing can be employed to make such unconventional shapes.

scholarly journals Preliminary Comparison of Properties between Ni-electroplated Stainless Steel Parts Fabricated with Laser Additive Manufacturing and Conventional Machining

2015 ◽  
Vol 78 ◽  
pp. 337-346 ◽  
Author(s):  
Mika Mäkinen ◽  
Eeva Jauhiainen ◽  
Ville-Pekka Matilainen ◽  
Jaakko Riihimäki ◽  
Jussi Ritvanen ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Laser Additive Manufacturing ◽  
Preliminary Comparison ◽  
Conventional Machining

Development of ODS Coating for High Temperature Turbine Components Using DED Additive Manufacturing

2018 ◽  
Author(s):  
Eric Chia ◽  
Bruce S. Kang ◽  
Min Zheng ◽  
Yang Li ◽  
Minking Chyu
Keyword(s):  
High Temperature ◽  
Additive Manufacturing ◽  
Gas Turbine ◽  
Thermally Grown Oxide ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Internal Cooling ◽  
Test Results ◽  
Dispersion Strengthening ◽  
Thermal Cycles

Current and future designs for advanced turbine systems, such as Integrated Gasification Combined Cycle (IGCC), advanced Natural Gas Combined Cycle (NGCC), and the emerging supercritical CO2 (SCO2) systems require increasing turbine inlet temperature (TIT), which is well beyond the substrate melting temperature. The well-known approach is coating the turbine blade with thermal barrier coatings (TBC) combined with internal cooling channel in the substrate. However, due to thermally grown oxide (TGO) and thermal expansion mismatch stresses, TBC spallation failure is a major concern. Furthermore, neither the ceramic coating layer nor the metallic bond coat in current TBC system can provide structural support to house the internal cooling channels. In this research, a method to fabricate high temperature protective structural coating on top of critical gas turbine components by additive manufacturing (AM) technique using oxide dispersion strengthening (ODS) metal powder is presented. A novel combined mechanochemical bonding (MCB) plus ball milling process is utilized to produce near spherical and uniformly alloyed ODS powders. AM-processed ODS coating by direct energy deposition (DED) method on MAR-247 substrate, with laser powers from 100W to 200W were carried out. The ODS coated samples were then subjected to thermal cyclic loadings for over 2200 cycles. For comparison, in our earlier studies, under the same cyclic testing condition, typical tested TBC coupons showed spallation failure after ∼400 cycles. Correlation of the measured ODS coating Young’s modulus using a unique non-destructive micro-indentation testing method with evolution of the ODS microstructures are studied to identify optimum AM processing parameters for best performance of the ODS samples. In particular, stability of secondary γ′ phase in the ODS coating after thermal cycles is analyzed. Test results revealed a thin steady durable alpha alumina oxide layer on the best performance ODS samples. After 2,200 thermal cycles, strong bonding at ODS/substrate interface is also maintained for most of the ODS coated samples. Test results also showed stable substrate microstructure due to the protective ODS coating even after 2,200 thermal cycles. These preliminary test results showed strong potential for applications of AM-assisted ODS coating on advanced gas turbine components.

scholarly journals Effect of additive manufacturing on fatigue crack propagation of a gas turbine superalloy

2019 ◽  
Vol 23 ◽  
pp. 215-220
Author(s):  
Mattias Calmunger ◽  
Robert Eriksson ◽  
Thomas Lindström ◽  
Daniel Leidermark
Keyword(s):  
Fatigue Crack ◽  
Additive Manufacturing ◽  
Crack Propagation ◽  
Gas Turbine ◽  
Fatigue Crack Propagation

scholarly journals Gas Turbine Rotor Disc Repair-Case History

1998 ◽  
Author(s):  
Zdzislaw Mazur ◽  
Janusz Kubiak
Keyword(s):  
Gas Turbine ◽  
Stress Relief ◽  
Repair Process ◽  
Turbine Rotor ◽  
Second Stage ◽  
Welding Technology ◽  
Disc Repair ◽  
Stage 1 ◽  
In Situ Repair

The 20.65 MW gas turbine experienced catastrophic damage. The failure occurred at the first stage buckets and resulted in damage of the all buckets of this stage. Five rotor disc grooves were also seriously damaged. Additionally, all second stage buckets, first and second stage nozzles, shroud segments, the No 2 bearing casing (turbine side), compressor moving blades, and other elements were damaged. Due to urgent power generation needs, it was decided to repair a seriously damaged stage 1 rotor disc in-situ, and replace all the other damaged parts. The development of a propietary welding technology for the in-situ repair of the five damaged disc grooves without disc disassembly, and of in-situ disc grooves’ mechanized machining is fully described. The repair process included the removal of damaged grooves, method of groove restoration by welding deposition, stress relief and groove machining to recover their original geometry. After rotor disc repair and assembly, the rotor was put back into service. The approach to the repair of the rotor disc damage has been successful. It enabled significant reductions in expenditure on replacement parts and a reduction of outage time to be achived.

THE MICROSTRUCTURAL ANALYSIS OF THE EFFECT OF FIC ON GAS TURBINE BLADES

2006 ◽  
Vol 20 (25n27) ◽  
pp. 4135-4140 ◽  
Author(s):  
HYUNG-ICK KIM ◽  
YONG HUH ◽  
HONG-SUN PARK ◽  
CHANG-SUNG SEOK ◽  
MOON-YOUNG KIM
Keyword(s):  
Mechanical Properties ◽  
Gas Turbine ◽  
Operation Mode ◽  
Turbine Blades ◽  
Microstructural Analysis ◽  
Repair Process ◽  
Optical Microscope ◽  
Important Indicator ◽  
Nickel Based Superalloy ◽  
Phase Coarsening

Advancements in superalloys permit hot gas path components to operate for many thousands of hours under severe centrifugal, thermal and vibratory stresses. The blade of a gas turbine must withstand the most severe combination of temperature, stress, and environment. After a certain period of operation, the blade is damaged by the turbine operation mode. To recover the similar initial mechanical properties, the blade of nickel-based superalloy component undergoes a replacement repair process. A fluoride ion cleaning (FIC) process is used to assist in the successful welding repair of nickel-based superalloy components. This work is to study the FIC influence on a gas turbine blade that was serviced 25,748 equivalent operating hour (EOH) after first overhaul. The blades, including the fractured regions were obtained from a plant. The conditions of blade samples were observed by optical microscope and SEM, and the chemical composition of the flaws in the blade was investigated by EDS. γ′ phase morphology is also an important indicator of the mechanical properties of blades at the high temperatures. The blade condition was examined from morphology and size of the γ′ phase, because the γ′ phase coarsening rate depends largely on the exposure time and temperature.

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