AGT101/ATTAP Ceramic Technology Development

1989 ◽  
Vol 111 (1) ◽  
pp. 158-167 ◽  
Author(s):  
G. L. Boyd ◽  
D. M. Kreiner
Keyword(s):  
Life Cycle Cost ◽  
Technology Development ◽  
Ceramic Technology ◽  
Ceramic Component ◽  
Component Reliability ◽  
Turbine Engine ◽  
Automotive Engine ◽  
Component Design ◽  
Technology Applications ◽  
Ceramic Components

The Garrett Turbine Engine Company/Ford Advanced Gas Turbine Program, designated AGT101, came to an end in June 1987. During this ceramic technology program, ceramic components were exposed to over 250 h of engine test. The 85-h test of the all-ceramic hot section to 1204C (2200F) was a significant accomplishment. However, this AGT101 test program also identified ceramic technology challenges that require continued development. These technology challenges are the basis for the five-year Advanced Turbine Technology Applications Project (ATTAP), which began in Aug. 1987. The objectives of this program include: (1) further development of analytical tools for ceramic component design utilizing the evolving ceramic material properties data base; (2) establishment of improved processes for fabricating advanced ceramic components; (3) development of improved procedures for testing ceramic components and test verification of design methods; and (4) evaluation of ceramic component reliability and durability in an engine environment. These activities are necessary to demonstrate that structural ceramic technology has the potential for competitive automotive engine life cycle cost and life.

scholarly journals ATTAP Ceramic Gas Turbine Technology Development

1992 ◽  
Author(s):  
J. R. Smyth ◽  
R. E. Morey
Keyword(s):  
Gas Turbine ◽  
Technology Development ◽  
Process Development ◽  
Department Of Energy ◽  
Ceramic Technology ◽  
Turbine Engine ◽  
Engineering Research ◽  
Technology Applications ◽  
Ceramic Components ◽  
Engine Testing

In the Advanced Turbine Technology Applications Project (ATTAP), Garrett Auxiliary Power Division (GAPD) continues to address critical technologies for the application of ceramics in gas turbine engines. Design methods and component and fabrication development are culminating in rig and engine testing to confirm ceramic technology development. Analytical methods for designing impact-resistant ceramic engine components have been verified in experiments, and improved regenerator seals and combustor designs have been tested. Engineered process development by selected subcontractors has resulted in delivery of high-quality ceramic components. All of these efforts are aimed at a planned all-ceramic turbine engine demonstration for 300 hours operation up to 2500F (1371C). ATTAP is a continuing program funded by the U.S. Department of Energy (DOE) Office of Transportation Technologies and administered by the NASA-Lewis Engineering Research Center under Contract No. DEN3-335.

Progress on the Advanced Turbine Technology Applications Project (ATTAP)

1994 ◽  
Author(s):  
S. G. Berenyi
Keyword(s):  
Life Cycle Cost ◽  
High Speed ◽  
Design Procedure ◽  
Department Of Energy ◽  
Laboratory Evaluation ◽  
Ceramic Component ◽  
Turbine Engine ◽  
Oak Ridge ◽  
Turbine Inlet ◽  
Ceramic Components

This technology project, sponsored by the U.S. Department of Energy, is intended to advance the technological readiness of the ceramic automotive gas turbine engine. Of the several technologies requiring development before such an engine becomes a commercial reality, structural ceramic components represent the greatest technical challenge, and are the prime project focus. The ATTAP aims at developing and demonstrating such ceramic components that have a potential for: (1) competitive automotive engine life cycle cost and (2) operating for 3500 hr in a turbine engine environment at turbine inlet temperatures up to 1371°C (2500°F). Allison is addressing the ATTAP goal using internal technical resources, an extensive technology and data base from General Motors (GM), technical resources from several subcontracted domestic ceramic suppliers, and supporting technology developments from Oak Ridge and other federal programs. The development activities have resulted in the fabrication and delivery of numerous ceramic engine components, which have been characterized through laboratory evaluation, cold spin testing, hot rig testing, and finally through engine testing as appropriate. These component deliveries are the result of the ATTAP design/process development/fabrication/characterization/test cycles. Ceramic components and materials have been characterized in an on-going program using nondestructive and destructive techniques. So far in ATTAP, significant advancements include: • evolution of a correlated design procedure for monolithic ceramic components • evolution of materials and processes to meet the demanding design and operational requirements of high temperature turbines • demonstration of ceramic component viability through thousands of hours of both steady-slate and transient testing while operating at up to full design speed, and at turbine inlet temperatures up to 1371°C (2500°F) • completion of hundreds of hours of durability cyclic testing utilizing several “all ceramic” gasifier turbine assemblies • demonstration of ceramic rotor survivability under conditions of extreme foreign object ingestion, high speed turbine tip rub, severe start-up transients, and a very demanding durability cycle In addition to the ceramic component technology, progress has been made in the areas of low emission combustion technology and regenerator design and development.

Design of Ceramic Components for an Advanced Micro-Turbine Engine

2004 ◽  
Author(s):  
Bill Tredway ◽  
Jun Shi ◽  
John Holowczak ◽  
Venkata Vedula ◽  
Connie E. Bird ◽  
...  
Keyword(s):  
Thermal Stresses ◽  
Ceramic Materials ◽  
Turbine Rotor ◽  
Component Reliability ◽  
Turbine Engine ◽  
Component Design ◽  
Temperature Capability ◽  
Ceramic Components ◽  
Micro Turbine ◽  
Engine Components

Ceramic components, due to their high temperature capability, allow significantly higher turbine inlet temperatures with minimal cooling. Hot-section engine components, including combustor, integral vane ring, integrally bladed turbine rotor, and turbine tip shroud were designed for an advanced micro-turbine engine, with special attention to attachment methods that minimize thermal stresses due to large differences between coefficients of thermal expansion between metallic and ceramic materials. Detailed aerodynamic, thermal and stress analyses were performed. Both steady state and transient conditions were evaluated to guide design decisions that lead to optimal component reliability and manufacturability. This paper describes the component design, analysis, and fabrication experiences with silicon based monolithic ceramic materials.

scholarly journals Ceramic Gas Turbine Technology Development

1996 ◽  
Author(s):  
M. L. Easley ◽  
J. R. Smyth
Keyword(s):  
Gas Turbine ◽  
Impact Resistance ◽  
Strain Gages ◽  
Ceramic Component ◽  
Advanced Ceramics ◽  
Turbine Engine ◽  
Commercial Viability ◽  
Component Design ◽  
Ceramic Components ◽  
The U.S

Under the U.S. Department Of Energy/National Aeronautics and Space Administration (DOE/NASA) funded Ceramic Turbine Engine Demonstration Program, AlliedSignal Engines is addressing the remaining critical concerns slowing the commercialization of structural ceramics in gas turbine engines. These issues include demonstration of ceramic component reliability, readiness of ceramic suppliers to support ceramic production needs, and enhancement of ceramic design methodologies. The AlliedSignal/Garrett Model 331-200[CT] Auxiliary Power Unit (APU) is being used as a ceramics test bed engine. For this program, the APU First-stage turbine blades and nozzles were redesigned using ceramic materials, employing the design methods developed during the earlier DOE/NASA funded Advanced Gas Turbine (AGT) and Advanced Turbine Technologies Application Project (ATTAP) programs. The present program includes ceramic component design, fabrication, and testing, including component bench tests and extended engine endurance testing and field testing. These activities will demonstrate commercial viability of the ceramic turbine application. In addition, manufacturing process scaleup for ceramic components to the minimum level for commercial viability will be demonstrated. Significant progress has been made during the past year. Engine testing evaluating performance with ceramic turbine nozzles has accumulated over 910 hours operation. Ceramic blade component tests were performed to evaluate the effectiveness of vibration dampers and high-temperature strain gages, and ceramic blade strength and impact resistance. Component design technologies produced impact-resistance design guidelines for inserted ceramic axial blades, and advanced the application of thin-film thermocouples and strain gages on ceramic components. Ceramic manufacturing scaleup activities were conducted by two ceramics vendors, Norton Advanced Ceramics (East Granby, CT) and AlliedSignal Ceramic Components (Torrance, CA). Following the decision of Norton Advanced Ceramics to leave the program, a subcontract was initiated with the Kyocera Industrial Ceramics Company Advanced Ceramics Technology Center (Vancouver, WA). The manufacturing scaleup program emphasizes improvement of process yields and increased production rates. Work summarized in this paper was funded by the U.S. Dept. Of Energy (DOE) Office of Transportation Technologies, part of the Turbine Engine Technologies Program, and administered by the NASA Lewis Research Center, Cleveland, OH under Contract No. DEN3-335.

scholarly journals ATTAP/AGT101 Ceramics Technology Update

1989 ◽  
Author(s):  
G. L. Boyd ◽  
D. M. Kreiner
Keyword(s):  
Data Base ◽  
Gas Turbine ◽  
Design Methods ◽  
Ceramic Technology ◽  
Fabrication Technology ◽  
Ceramic Component ◽  
Technology Design ◽  
Methods Development ◽  
Technology Applications ◽  
Ceramic Components

The feasibility of applying ceramics to the gas turbine was demonstrated during the AGT101 Program, when over 250 hours were accumulated on ceramic components in engine tests at temperatures up to 1204C (2200F). The follow-on program, designated the Advanced Turbine Technology Applications Project (ATTAP), began in late August 1987 to further develop ceramic technology. This program addresses ceramic component fabrication technology, design methods development and the supporting data base, and verification of ceramic component durability in an operating engine environment. These technologies must be demonstrated so that a commercialization development decision can be made at the end of ATTAP.

scholarly journals Development of Ceramic Gas Turbine Components for the CGT301 Engine

1996 ◽  
Author(s):  
Mitsuru Hattori ◽  
Tsutomu Yamamoto ◽  
Keiichiro Watanabe ◽  
Masaaki Masuda
Keyword(s):  
Gas Turbine ◽  
Technology Development ◽  
Turbine Blades ◽  
High Heat ◽  
Turbine Engine ◽  
Development Organization ◽  
All Ceramic ◽  
New Energy ◽  
Ceramic Components ◽  
Resistant Ceramic

NGK Insulators, Ltd. (NGK) has undertaken the research and development on the fabrication processes of high-heat-resistant ceramic components for the CGT301, which is a 300kW recuperative industrial ceramic gas turbine engine. This program is under the New Sunshine Project, funded by the Ministry of International Trade and Industry (MITI), and has been guided by the Agency of Industrial Science & Technology (AIST) since 1988. The New Energy and Industrial Technology Development Organization (NEDO) is the main contractor. The fabrication techniques for ceramic components, such as turbine blades, turbine nozzles, combustor liners, gas-path parts, and heat exchanger elements, for the 1,200°C engine were developed by 1993. Development for the 1,350°C engine has been underway since 1994. The baseline conditions for fabricating of all ceramic components have been established. This paper reports on the development of ceramic gas turbine components, and the improved accuracies of their shapes as well as improved reliability from the results of the interim appraisal conducted in 1994.

Advanced Turbine Technology Applications Project (ATTAP): Overview, Status, and Outlook

1989 ◽  
Author(s):  
Philip J. Haley
Keyword(s):  
Process Development ◽  
Feasibility Studies ◽  
Turbine Rotor ◽  
Flow Path ◽  
Department Of Energy ◽  
General Motors ◽  
Turbine Engine ◽  
Technology Applications ◽  
Ceramic Components ◽  
Engine Testing

The ATTAP aims at proving the performance and life of structural ceramic components in the hot gas path of an automotive gas turbine engine. This Department of Energy (DOE)-sponsored, NASA-managed program is being addressed by a General Motors (GM) team drawing expertise from the Advanced Engineering Staff (AES) and from Allison. The program includes design, process development and fabrication, rig and engine testing, and iterative development of selected key ceramic components for the AGT-5 engine. A reference powertrain design (RPD) based on this engine predicts acceleration, driveability, and fuel economy characteristics exceeding those of both current engines and the DOE goals. A low-apsect-ratio ceramic turbine rotor design has been successfully engine-demonstrated at 2200°F and 100% speed, including survival of impact and other hostile flow path conditions. Turbine flow path components have been designed for the 2500°F cycle, using improved monolithic ceramics targeted for Year 2 fabrication. Major development/fabrication efforts have been subcontracted at Carborundum, GTE Labs, Corning Glass, Garrett Ceramic Components, and Manville. Feasibility studies were initiated with Ceramics Process Systems and Drexel University.

Advanced Turbine Technology Applications Project (ATTAP): Overview, and Ceramic Component Technology Status

1991 ◽  
Author(s):  
Philip J. Haley
Keyword(s):  
High Speed ◽  
High Volume ◽  
Department Of Energy ◽  
High Yield ◽  
Design System ◽  
Ceramic Component ◽  
Forming Process ◽  
Technology Applications ◽  
Ceramic Components ◽  
Monolithic Ceramics

The automotive gas turbine’s (AGT) significant potential payoffs in fuel economy, emissions, and alternate fuels usage continue to motivate development activities worldwide. The U.S. Department of Energy-sponsored, NASA-managed Advanced Turbine Technology Applications Project (ATTAP) focuses on developing critical AGT structural ceramic component technologies. The area of greatest challenge is that of cost-effective, near-net-shape, high-volume, high-yield manufacturing processes. Process physics modeling and Taguchi analyses are affording substantial progress, and new processes are being explored. Laboratory characterization is building a shared materials data base among Allison, Garrett, Government labs, and ceramic manufacturers. General Motors (GM) has logged over 700 test hours with ceramic components in hot gasifier rigs during ATTAP. A key ATTAP milestone was addressed by successfully demonstrating full goal temperature and speed (2500°F rotor inlet at 100% shaft speed) with ceramic components. Fast-fracture ceramic component design tools are well correlated. Although time-dependent data and mechanistic models exist, a validated design system for such phenomena does not, and is a pressing need. Damage tolerance and impact resistance have been substantially addressed through tailored component designs, tougher monolithic ceramics, and increased ceramic strengths. Ceramic turbine rotors are now continuing to run after various substantial impacts, and after chipping damage. Ceramic-ceramic and ceramic-metal interfacing is being addressed by minimizing components’ joints, and by other DOE-sponsored work on joining models, processes, and materials. The extruded regenerator disk is a continuing goal which requires both forming process and materials technology development. Controlling turbine tip clearances and tolerating tip rubs are key technologies. GM has demonstrated clearance control schemes, as well as rotor survivability to high speed/temperature tip rubs. Several noteworthy ceramic materials reflect the rapid progress over the past decade of monolithic ceramics, especially the Si3N4 family. GM forecasts achieving ATTAP engine cyclic durability goals.

scholarly journals 300 kW Class Ceramic Gas Turbine Development (CGT 301)

1994 ◽  
Author(s):  
Masaru Sakakida ◽  
Tadashi Sasa ◽  
Kazuho Akiyama ◽  
Shinya Tanaka
Keyword(s):  
Gas Turbine ◽  
Axial Flow ◽  
Second Phase ◽  
Test Results ◽  
Ceramic Component ◽  
Component Design ◽  
All Ceramic ◽  
Ceramic Components ◽  
Primary Type ◽  
Metallic Parts

CGT 301 is a recuperated, single-shaft, ceramic gas turbine for cogeneration capable of continuous full load application. In order to reduce its size, thermal stress, and deformations, ceramic parts are designed axi-symmetrically. The combustor is located on a shaft axis just before the turbine, therefore it does not have a large scroll. The turbine is a two-stage axial flow-type with ceramic blades. For the first phase of the program, the primary-type gas turbine with all-metallic parts was fabricated and tested under various conditions. The test results confirmed the rotation stability of the gas turbine. After the test of preliminary metallic gas turbine, all-ceramic parts were fabricated and various tests were carried out to confirm their reliability. The configuration and structure of the ceramic turbine were improved based on the data obtained from the tests of the primary-type gas turbine and the fundamental tests for ceramic components. The primary-type ceramic gas turbine of TIT 1200°C was designed and fabricated for the second phase of the program. This paper outlines the concept of the ceramic component design, test results of ceramic parts in the hot section, and the engine test.

scholarly journals ATTAP/AGT101: Year 2 Progress in Ceramic Technology Development

1990 ◽  
Author(s):  
J. R. Kidwell ◽  
L. J. Lindberg ◽  
R. E. Morey
Keyword(s):  
Technology Development ◽  
Impact Damage ◽  
Damage Threshold ◽  
Ceramic Materials ◽  
Department Of Energy ◽  
Ceramic Technology ◽  
Ceramic Component ◽  
Lean Burn ◽  
Turbine Inlet ◽  
Particle Separator

In the second year of a five-year Department of Energy (DOE) funded program, the Advanced Turbine Technology Applications Project (ATTAP) pushed ceramic automotive gas turbine technology state-of-the-art forward in: • Ceramic materials assessment and characterization • Ceramic impact damage assessment • Ceramic combustor evaluation • Turbine inlet particle separator development • Impact-tolerant turbine designs • Net-shape ceramic component fabrication Materials characterization progressed from specimens to cut-up components. Impact damage threshold velocities were measured, using graphite projectiles against specimens and full-size rotors. Lean-burn ceramic combustor evaluations included ignition and carbon formation tests with DF-2, JP-4, and ethanol fuels. A third-generation ceramic turbine inlet particle separator demonstrated 97.5-percent effectiveness against rotor-damaging graphite particles. Improved ceramic component design capabilities are providing lower-stress components for incorporation into the critical hot flow path. Component fabrication development focussed on net-shape forming techniques, using Taguchi experiments. ATTAP is funded by DOE and administered by NASA under Contract DEN3-335.

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