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.

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, 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.

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.

Boundary Conditions for Ceramic Turbine Components: Analytical Prediction and Test Validation

1999 ◽  
Author(s):  
Hamid Bagheri ◽  
Oscar Jimenez
Keyword(s):  
Finite Element ◽  
Boundary Conditions ◽  
Gas Turbines ◽  
Department Of Energy ◽  
Analytical Prediction ◽  
Finite Element Analyses ◽  
Ceramic Component ◽  
Engine Operation ◽  
Component Development ◽  
Ceramic Components

Ceramics allow gas turbine engines to run at higher temperatures to increase power and efficiency. Ceramic component development is therefore required to understand transient thermal behavior and temperature distributions. As a part of contract with US Department of Energy (DOE), a series of finite element analyses were completed and a Solar Turbine (Solar) Centaur 50S engine was tested to characterize this behavior. To better understand the interaction between the metallic and ceramic components during engine operation, a finite element model was prepared. The boundary conditions for this model were estimated analytically or using existing test data. To verify the boundary conditions in the vicinity of uncooled ceramic components, two engine tests were performed on a metallic engine simulating the ceramic engine configuration. The Solar Centaur 50S engine normally operates at 1010°C with all metallic components. A Centaur 50S eagine was retrofitted with a ceramic combustor liner and uncooled first stage turbine blades and nozzles. Two tests were conducted at firing temperatures of 1095 and 980°C. Using metallic components saved time, reduced the complexity of working with ceramic components, and eliminated some of the difficulties of attaching instrumentation to ceramic parts. Component temperatures were measured and used in the finite element analyses to help predict blade tip clearances, ceramic component temperatures, stresses and ultimately component lives. The strategy undertaken and results presented herein provided a reliable and effective approach to ceramic component development and provides critical temperature information in the qualification process for ceramic gas turbines.

On Saw-Tooth Chip Formation in High Speed Cutting GH4169

2007 ◽  
Vol 10-12 ◽  
pp. 359-363 ◽  
Author(s):  
Dong Jin Zhang ◽  
Gang Liu ◽  
X. Sun ◽  
Ming Chen
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
High Yield ◽  
Forming Process ◽  
Element Analysis ◽  
High Speed Cutting ◽  
Nickel Based Superalloy ◽  
Wide Range

The nickel-based superalloy GH4169 is a typical difficult-to-cut material, but it has been used in a good many kinds of aeronautical key structures because of its high yield stress and anti-fatigue performance at the temperature below 650°C. In this paper, finite element method (FEM) was introduced to study the saw-tooth chip forming process in detail when machining nickel-based superalloy GH4169. By the way of Lagrangian visco-elastic plastic approach, adiabatic shear band (ASB) was simulated in high speed machining condition by general commercial finite element code, and the mechanism of the adiabatic shearing phenomenon at primary shear zone was analyzed with the help of finite element analysis (FEA). The comprehensive comparisons of saw-tooth chip morphology under a wide range of cutting speed were also presented.

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 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 Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4143
Author(s):  
Youzheng Cui ◽  
Shenrou Gao ◽  
Fengjuan Wang ◽  
Qingming Hu ◽  
Cheng Xu ◽  
...  
Keyword(s):  
High Speed ◽  
Large Scale ◽  
Volume Fraction ◽  
Simulation Analysis ◽  
Cutting Temperature ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
High Wear Resistance ◽  
Element Analysis

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc= 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

Machine Learning Acoustic Emission Based Monitoring of Cold Forging for Smart Manufacturing: A Review

2021 ◽  
Vol 2 (3) ◽  
Keyword(s):  
Machine Learning ◽  
Acoustic Emission ◽  
Product Quality ◽  
High Speed ◽  
High Rate ◽  
Cold Forging ◽  
Smart Manufacturing ◽  
Forming Process ◽  
Cold Forming ◽  
Effective Manner

Cold forging is a high-speed forming technique used to shape metals at near room temperature. and it allows high-rate production of high strength metal-based products in a consistent and cost-effective manner. However, cold forming processes are characterized by complex material deformation dynamics which makes product quality control difficult to achieve. There is no well defined mathematical model that governs the interactions between a cold forming process, material properties, and final product quality. The goal of this work is to provide a review for the state of research in the field of using acoustic emission (AE) technology in monitoring cold forging process. The integration of AE with machine learning (ML) algorithms to monitor the quality is also reviewed and discussed. It is realized that this promising technology didn’t receive the deserving attention for its implementation in cold forging and that more work is needed.

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