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.

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.

scholarly journals AGT101 Advanced Gas Turbine Technology Update

1984 ◽  
Author(s):  
J. R. Kidwell ◽  
D. M. Kreiner ◽  
R. A. Rackley ◽  
J. L. Mason
Keyword(s):  
United States ◽  
Gas Turbine ◽  
The United States ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
Screening Tests ◽  
Inlet Temperature ◽  
United States Department ◽  
Turbine Engine ◽  
Engine Testing

The Garrett/Ford Advanced Gas Turbine (AGT) Technology Project, authorized under NASA Contract DEN3-167, is sponsored by and is part of the United States Department of Energy Gas Turbine Highway Vehicle System Program. Program effort is oriented at providing the United States automotive industry the high risk long-range technology necessary to produce gas turbine powertrains for automobiles that will have reduced fuel consumption and reduced environmental impact. The AGT101 power section is a 74.6 kW (100 hp), regenerated single-shaft gas turbine engine operating at a maximum turbine inlet temperature of 1371°C (2500°F). Maximum rotor speed is 10,472 rad/sec (100,000 rpm). All high temperature components, including the turbine rotor, are ceramic. Development has progressed through aerothermodynamic testing of all components with compressor and turbine performance goals achieved. Some 200 hours of AGT101 testing has been accumulated at a nominal 871°C (1600°F) on three metal engines. Individual and collective ceramic component screening tests have been successfully accomplished at temperatures up to 1149°C (2100°F). Ceramic turbine rotors have been successfully cold spun to the required proof speed of 12,043 rad/sec (115,000 rpm), a 15-percent overspeed, and subjected to dynamic thermal shock tests simulating engine conditions. Engine testing of the ceramic structures and of the ceramic turbine rotor is planned in the near future.

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.

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 Ceramic Stationary Gas Turbine Development Program — Fifth Annual Summary

1998 ◽  
Author(s):  
Jeffrey R. Price ◽  
Oscar Jimenez ◽  
Les Faulder ◽  
Bryan Edwards ◽  
Vijay Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Development Program ◽  
Field Testing ◽  
The United States ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
Inlet Temperature ◽  
United States Department ◽  
Performance Improvements ◽  
Ceramic Components

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of metallic hot section components with ceramic parts. The program focuses on design, fabrication, and testing of ceramic components, generating a materials properties data base, and applying life prediction and nondestructive evaluation (NDE). The development program is being performed by a team led by Solar Turbines Incorporated, and which includes suppliers of ceramic components, U.S. research laboratories and an industrial cogeneration end user. The Solar Centaur 50S engine was selected for the development program. The program goals included an increase in the turbine rotor inlet temperature (TRIT) from 1010°C (1850°F) to 1121°C (2050°F), accompanied by increases in thermal efficiency and output power. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The ceramic liners are also expected to lower the emissions of NOx and CO. Under the program uncooled ceramic blades and nozzles have been inserted for currently cooled metal components in the first stage of the gas producer turbine. The louvre-cooled metal combustor liners have been replaced with uncooled continuous-fiber reinforced ceramic composite (CFCC) liners. Modifications have been made to the engine hot section to accommodate the ceramic parts. To-date all first generation designs have been completed. Ceramic components have been fabricated, and are being tested in rigs and in the Centaur 50S engine. Field testing at an industrial co-generation site was started in May, 1997. This paper will provide an update of the development work and details of engine testing of ceramic components under the program.

Analysis and Testing of Air-Cooled Turbine Rotor and Stator Blades

1965 ◽  
Author(s):  
H. E. Helms ◽  
C. W. Emmerson
Keyword(s):  
Turbine Rotor ◽  
Problem Definition ◽  
Blade Design ◽  
Rigorous Analysis ◽  
Cooling Effectiveness ◽  
Turbine Engine ◽  
Turbine Stator ◽  
Data Problem ◽  
Engine Testing ◽  
Combined Cooling

Advancing turbine engine technology requires air-cooled turbines. Cooling mechanisms applied must be exploited in a practical manner to obtain maximum cooling effectiveness. Cooled turbine stator and rotor blade design requires rigorous analysis supplemented by verifying experimental data. Problem definition, analysis techniques, material application, cascade and engine testing, and correlation of data are presented for air-cooled turbines. Convection, impingement, film, transpiration, and combined cooling mechanisms are reviewed.

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 Progress on the Advanced Turbine Technology Applications Project (ATTAP), and Automotive Gas Turbine Outlook

1992 ◽  
Author(s):  
Philip J. Haley
Keyword(s):  
Gas Turbine ◽  
High Speed ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
General Motors ◽  
Heat Management ◽  
Static Structure ◽  
Durability Test ◽  
Refractory Fiber ◽  
Injection Molded

Of the four key technology areas attendant to the automotive gas turbine (ACT), structural ceramic components are the prime focus of the Department of Energy (DOE)-sponsored, NASA-managed ATTAP. The General Motors (GM) ATTAP team first focused on the ceramic gasifier turbine rotor, and in 1990 achieved full design temperature (2500°F TIT) at 100%N1 (gasifier speed). Four generations of axial-rotor design have led to such success, which also includes demonstrated resistance to foreign object impact; functionality after impact and minor damage; survivability in high-speed tip rub; and a 1000-hour durability demonstration. The ceramic gasifier turbine static structure, comprising scroll and vaneset (plus other support components), has also been successfully demonstrated at full (2500°F) design conditions, including successful completion of a 100-hour durability test of an all-ceramic gasifier stage. This major contractual milestone was completed during 1991. These successes represent fundamental technology progress, not only in the GM designs, but in the materials and processes implemented by the Kyocera Corporation, Norton/TRW Ceramics, and GTE Labs. Heat management (regenerator system and thermal insulation) and combustion are other key AGT technologies. Ceramic regenerator disk efforts with Corning focus on developing extrusion technology in concert with evaluation of four ceramic material systems, to provide a disk with the requisite geometry, strength, survivability, and cost characteristics. Insulation activities with Manville target developing a ceramic refractory fiber-based system, which is wet injection molded directly in-place, and has the required thermal, adhesion, durability, and erosion properties. During 1991 a turbine engine component was successfully injection molded with this system. Some ATTAP effort has been directed toward design of a prevaporizing/premixing combustor to meet the California 0.2 gm/mile NOx standard.

scholarly journals Ceramic Applications in Turbine Engines (CATE) Development Testing

1983 ◽  
Author(s):  
H. E. Helms ◽  
S. R. Thrasher
Keyword(s):  
Gas Turbine ◽  
Process Development ◽  
Gas Turbine Engine ◽  
Turbine Engines ◽  
Development Work ◽  
Gas Turbine Engines ◽  
Turbine Engine ◽  
Proof Testing ◽  
Component Development ◽  
Ceramic Components

The objective of the CATE program was to apply ceramic components to the hot flow path of an existing vehicular gas turbine engine and thereby demonstrate the feasibility of structural ceramic components. To accomplish this the Allison IGT 404-4 gas turbine engine has operated at successively higher temperatures made possible by the introduction of ceramic components with performance and component durability demonstrations. Extensive ceramic material characterization, supplier process development work, development of non-destructive inspection (NDI) techniques, rig ceramic component development and proof testing, and engine demonstration testing have been conducted. This paper describes the CATE Project concept for development testing of ceramic components for use in vehicular gas turbine engines. Included will be the approach to development testing, a description of the CATE GT 404 engine and the ceramic components designed for that engine, a summary of the development test experience accumulated on the ceramic components, an assessment of the results and benefits gained from the program, and recommendations for follow-on component development work.

Development and Characterization of High Strength SiC Rotors

1991 ◽  
Author(s):  
R. W. Ohnsorg ◽  
G. V. Srinivasan
Keyword(s):  
Injection Molding ◽  
Gas Turbine ◽  
Slip Casting ◽  
High Strength ◽  
Cold Isostatic Pressing ◽  
General Motors ◽  
Injection Molding Process ◽  
Molding Process ◽  
Turbine Engine ◽  
Technology Applications

Sintered α-SiC (Hexoloy® SA*) turbine engine components have been fabricated by Carborundum for the Advanced Gas Turbine (AGT) Program and, more recently, for the Advanced Turbine Technology Applications Project (ATTAP) using three primary forming procedures — injection molding, cold isostatic pressing (CIP) followed by green machining, and slip casting. The near net-shape fabrication of injection molded AGT-100 radial rotors for the Allison Gas Turbine Division (AGTD) of General Motors Corporation and, more recently, AGT-5 axial rotors, has been demonstrated. The current emphasis at Carborundum is to refine the injection molding process, bringing it to a performance and reproducibility level sufficient for production needs. The process changes leading to increases in component strength from approximately 380 MPa (55 ksi) to 595 MPa (86 ksi) will be discussed, as well as investigation of the failure mechanism and proposed process modifications to enhance properties even further.

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