scholarly journals Ceramic Gas Turbine Technology Development and Applications

1993 ◽  
Author(s):  
J. R. Smyth ◽  
R. E. Morey ◽  
R. W. Schultze
Keyword(s):  
Gas Turbine ◽  
Impact Damage ◽  
Design Methods ◽  
Product Line ◽  
Structural Ceramics ◽  
Ceramic Component ◽  
Demonstration Program ◽  
Auxiliary Power ◽  
Ceramic Components ◽  
Engine Components

Under the ongoing DOE/NASA-funded Advanced Turbine Technology Applications Project (ATTAP), Garrett Auxiliary Power Division (GAPD) is continuing to address the issues of developing and applying structural ceramics to production gas turbine engines. Several critical technologies are being developed to advance this issue, including design methods development, component design, component fabrication, material characterization, and engine testing. The brittle nature of structural ceramics highlights concerns regarding impact damage. Through analysis and experimentation, design methods are being developed to improve the resistance of ceramic components to impact damage. Ceramic component designs now integrate these design methods into practice and proof testing methods are being developed to verify the results for actual engine components. Ceramic component fabrication processes are being optimized by selected subcontractors, resulting in deliveries of high-quality ceramic components which fully meet engine test needs. Verification of the component material properties is being achieved through comparisons of material property data from test bars cut from actual engine components with data generated from ceramic material test specimens. All these efforts are aimed at demonstrating endurance of the AGT101 all-ceramic turbine engine at the maximum operating temperature conditions up to 2500F (1371C). These critical ceramics technologies being developed under ATTAP are also providing a critical launch pad into production-oriented programs. GAPD has three concurrent programs underway, aimed at integrating ceramics into production Auxiliary Power Units (APUs). These include: installing and evaluating ceramic turbine nozzles under actual field conditions in a well-established product line (the 85 Series Ceramic Nozzle Demonstration Program); incorporating ceramic first-stage turbine stators and blades in a three-stage axial turbine APU (the 331-200 Ceramic Demonstration Program); and incorporation of a ceramic first-stage turbine stator in our latest APU design, the G250 Auxiliary Power Generation System (APGS) for the USAF F-22 fighter aircraft.

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 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.

Ceramic Stationary Gas Turbine Development Program: Third Annual Summary

1996 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Kenneth O. Smith ◽  
Bryan D. Edwards ◽  
Leslie J. Faulder ◽  
...  
Keyword(s):  
Silicon Nitride ◽  
Gas Turbine ◽  
Phase Ii ◽  
Development Program ◽  
Full Scale ◽  
Phase Iii ◽  
Ceramic Component ◽  
Ceramic Components ◽  
Engine Testing

The goal of the Ceramic Stationary Gas Turbine (CSGT) Development Program, under the sponsorship of the United States Department of Energy (DOE), Office of Industrial Technologies (OIT), is to improve the performance (fuel efficiency, output power, exhaust emissions) of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. The program, currently in Phase II focuses on detailed engine and component design, ceramic component fabrication and testing, establishment of a long term materials property data base, the development of supporting nondestructive evaluation (NDE) technologies, and the application of ceramic component life prediction. A 4000 hr engine field test is planned for Phase III of the program. This paper summarizes progress from January 1995 through January 1996. First generation designs of the primary ceramic components (first stage blades and nozzles, combustor liners) for the program engine, the Solar Centaur 50S, and of the secondary metallic components interfacing with the ceramic parts were completed. The fabrication of several components has been completed as well. These components were evaluated in rigs and the Centaur 50S test engine. NTI64 (Norton Advanced Ceramics) and GN-10 (AlliedSignal Ceramic Components) silicon nitride dovetail blades were cold and hot spin tested and engine tested at the baseline nominal turbine rotor inlet temperature (TRIT) of 1010°C. Full scale SiC/SiC continuous fiber-reinforced ceramic matrix composite (CFCC) liners (B.F. Goodrich Aerospace) were also rig tested and engine tested at the nominal baseline TRIT of 1010°C. One of the engine tests, incorporating both the GN-10 blades and the full scale SiC/SiC CFCC liners, was performed for 21.5 hrs (16 hrs at 100% load) with six start/stop cycles. A cumulative 24.5 hrs of engine testing was performed at the end of January, 1996. The ceramic components were in good condition following completion of the testing. Subscale Hexoloy® SA silicon carbide (Carborundum) and enhanced SiC/SiC CFCC (DuPont Lanxide Composites) and Al2O3/Al2O3 CFCC (Babcock & Wilcox) combustor liners were tested to evaluate mechanical attachment, durability and/or emissions reduction potential. The enhanced SiC/SiC CFCC of DuPont Lanxide Composites demonstrated superior durability in subscale combustor testing and this material was subsequently selected for the fabrication of full scale combustor liners for final engine rig testing in Phase II and field testing in Phase III of the program. Enhanced SiC/SiC CFCC liners also showed significantly reduced emissions of NOx and CO when compared with conventionally cooled subscale metallic liners. This observation is believed to apply generally to “hot wall” combustor substrates. The emissions results for the enhanced SiC/SiC CFCC liners were paralleled by similar emissions levels of NOx and CO monitored during engine testing with B.F. Goodrich Aerospace SiC/SiC CFCC combustor liners. NOx levels below 25 ppmv and CO levels below 10 ppmv were measured during the engine testing. Short term (1,000 hrs) creep testing of candidate ceramic materials under approximate nozzle “hot spot” conditions was completed and long term (5000–10,000 hrs) creep testing is in progress. The selected nozzle material, SN-88 silicon nitride, has survived over 5,500 hrs at 1288°C and 186 MPa stress at the end of January, 1996.

Status of Research and Development on Materials for Ceramic Gas Turbine Components

1992 ◽  
Vol 287 ◽  
Author(s):  
Minoru Matsui
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Structural Ceramics ◽  
Automobile Engine ◽  
Engine Components

Aggressive research and development has raised structural ceramics to a level where they are now of practical use as an alternative to metal. Major applications include use in automobile engine components, such as turbocharger rotors [1].

scholarly journals Ceramic Gas Turbine Technology Development

1994 ◽  
Author(s):  
M. L. Easley ◽  
J. R. Smyth
Keyword(s):  
Gas Turbine ◽  
Structural Integrity ◽  
Design Methods ◽  
Ceramic Technology ◽  
Nasa Lewis Research ◽  
Test Bed ◽  
Ceramic Component ◽  
Automotive Engine ◽  
Ceramic Design ◽  
Engine Testing

AlliedSignal Engines is addressing critical concerns slowing the commercialization of structural ceramics in gas turbine engines. These issues include ceramic component reliability, commitment of ceramic suppliers to support production needs, and refinement of ceramic design technologies. The stated goals of the current program are to develop and demonstrate structural ceramic technology that has the potential for extended operation in a gas turbine environment by incorporation in an auxiliary power unit (APU) to support automotive gas turbine development. AlliedSignal Engines changed the ATTAP ceramic engine test bed from the AGT101 automotive engine to the 331-200[CT] APU. The 331-200[CT] first-stage turbine nozzle segments and blades were redesigned using ceramic materials, employing design methods developed during the earlier DOE/NASA-funded Advanced Gas Turbine (AGT) and the ATTAP programs. The ceramic design technologies under development in the present program include design methods for improved resistance to impact and contact damage, assessment of the effects of oxidation and corrosion on ceramic component life, and assessment of the effectiveness of nondestructive evaluation (NDE) and proof testing methods to reliably identify ceramic parts having critical flaws. AlliedSignal made progress in these activities during 1993 ATTAP efforts. Ceramic parts for the 331-200[CT] engine have been fabricated and evaluated in component tests, to verify the design characteristics and assure structural integrity prior to full-up engine testing. Engine testing is currently underway. The work summarized in this paper was funded by the U.S. Dept. of Energy (DOE) Office of Transportation Technologies and administered by NASA-Lewis Research Center, under Contract No. DEN3-335.

scholarly journals Ceramic Gas Turbine Technology Development

1995 ◽  
Vol 117 (4) ◽  
pp. 783-791 ◽  
Author(s):  
M. L. Easley ◽  
J. R. Smyth
Keyword(s):  
Gas Turbine ◽  
Structural Integrity ◽  
Design Methods ◽  
Ceramic Technology ◽  
Nasa Lewis Research ◽  
Test Bed ◽  
Ceramic Component ◽  
Automotive Engine ◽  
Ceramic Design ◽  
Engine Testing

AlliedSignal Engines is addressing critical concerns slowing the commercialization of structural ceramics in gas turbine engines. These issues include ceramic component reliability, commitment of ceramic suppliers to support production needs, and refinement of ceramic design technologies. The stated goals of the current program are to develop and demonstrate structural ceramic technology that has the potential for extended operation in a gas turbine environment by incorporation in an auxiliary power unit (APU) to support automotive gas turbine development. AlliedSignal Engines changed the ATTAP ceramic engine test bed from the AGT101 automotive engine to the 331-200[CT] APU. The 331-200[CT] first-stage turbine nozzle segments and blades were redesigned using ceramic materials, employing design methods developed during the earlier DOE/NASA-funded Advanced Gas Turbine (AGT) and the ATTAP programs. The ceramic design technologies under development in the present program include design methods for improved resistance to impact and contact damage, assessment of the effects of oxidation and corrosion on ceramic component life, and assessment of the effectiveness of nondestructive evaluation (NDE) and proof testing methods to reliably identify ceramic parts having critical flaws. AlliedSignal made progress in these activities during 1993 ATTAP efforts. Ceramic parts for the 331-200[CT] engine have been fabricated and evaluated in component tests, to verify the design characteristics and assure structural integrity prior to full-up engine testing. Engine testing is currently under way. The work summarized in this paper was funded by the U.S. Dept. of Energy (DOE) Office of Transportation Technologies and administered by NASA-Lewis Research Center, under Contract No. DEN3-335.

scholarly journals Current Status of Industrial and Automotive Ceramic Gas Turbine R&D in Japan

1991 ◽  
Author(s):  
Soichi Nagamatsu ◽  
Kazuyuki Mizuhara ◽  
Yukio Matsuda ◽  
Akio Iwanaga ◽  
Shoji Ishiwata
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Technology Development ◽  
Ceramic Materials ◽  
Current Status ◽  
Inlet Temperature ◽  
Development Organization ◽  
Design Concepts ◽  
Ceramic Components ◽  
Engine Components

The current status of Japan’s national Ceramic Gas Turbines (CGTs) projects is overviewed. The Japanese Ministry of International Trade and Industry (MITI) is conducting two national R&D projects on CGT. These include a project on 300kW industrial CGTs for co-generation and mobile power generation use and a project on 100kW CGT for automotive use. The 300kW project was started in 1988, and is scheduled to develop three kinds of CGTs over nine years. The New Energy and Industrial Technology Development Organization (NEDO) is the main contractor, and three groups of private industries are sub contractors. Three national research institutes are involved in the project to conduct supportive research of ceramic materials and engine components. The 100kW project has started in 1990, and is scheduled to develop a single shaft automotive CGT over seven years. Petroleum Energy Center (PEC) and JARI are the main contractors with the cooperation of several petroleum and automotive companies. The goals for the two projects are 42% and higher for thermal efficiency at a turbine inlet temperature of 1350C. Such targets could not be achieved without applying high temperature ceramics to the engine components. Therefore many R&D objectives are directed towards developing the ceramic components which have a higher flexure strength and fracture toughness. Currently, 300kW base metal gas turbine engines are being developed to prove the design concepts. Blade shapes suitable to ceramics are being studied by the FEM method. Forming and manufacturing large components are also being studied, and some ceramics components have been successfully made.

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.

Ceramic Gas Turbine Technology Development

1995 ◽  
Author(s):  
M. W. Rettler ◽  
M. L. Easley ◽  
J. R. Smyth
Keyword(s):  
Gas Turbine ◽  
Scale Up ◽  
Nasa Lewis Research ◽  
Test Bed ◽  
Ceramic Component ◽  
Demonstration Program ◽  
Component Reliability ◽  
Turbine Engine ◽  
Engine Testing ◽  
The U.S

Under the U.S. Dept. of Energy/National Aeronautics and Space Administration (DOE/NASA) funded Ceramic Turbine Engine Demonstration Project, formerly the Advanced Turbine Technology Applications Project (ATTAP), 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 development of ceramic design technologies. The AlliedSignal/Garrett Model 331-200[CT] Auxiliary Power Unit (APU) is being used as a ceramics test bed engine. The 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 ATTAP programs. Ceramic engine components have been fabricated and are now being evaluated in laboratory engine testing. The fabrication processes for these components will provide the framework for a demonstration of manufacturing process scale-up to the minimum level for commercial viability. The laboratory engine testing is helping to refine the component designs and focus the development of ceramic component technologies. Extended engine endurance testing and field testing in commercial aircraft is planned to demonstrate ceramic component reliability. Significant progress has been made during 1994. An engine with ceramic turbine nozzles was successfully operated and engine tests in the laboratory are continuing to gather useful data. An engine equipped with ceramic blades was also tested, but blade fractures occurred, interrupting operation. An extensive investigation has identified possible vibration and contact problems. Investigative evaluation efforts are continuing to identify the problem source and determine go-forward plans for ceramic blade development. Component design technologies have progressed in the areas of modeling particle impact pulverization, development of a ceramic hot corrosion environmental life model, and methods for evaluating ceramic contact damage. The planned ceramic manufacturing scale-up was initiated with two ceramics vendors, Norton Advanced Ceramics (East Granby, CT) and AlliedSignal Ceramic Components (Torrance, CA). The scaleup demonstration program is emphasizing improvement of ceramic processing yields and increased production rates. Work summarized in this paper was funded by the U.S. Dept. of Energy (DOE) Office of Transportation Technologies, as part of the Turbine Engine Technologies Program, and administered by the NASA Lewis Research Center, Cleveland, OH under Contract No. DEN3-335.

Ceramic Stationary Gas Turbine Development Program: Second Annual Summary

1995 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Paul F. Norton ◽  
Bryan D. Edwards
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Fatigue Testing ◽  
The United States ◽  
United States Department ◽  
Ceramic Component ◽  
Support Structure ◽  
Engine Operation ◽  
Ceramic Components ◽  
Combustor Liner

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 hot section components with ceramic parts. Solar Turbines Incorporated leads a team that includes major U.S. and offshore suppliers of ceramic components, recognized test laboratories and a cogeneration enduser to develop and demonstrate ceramic insertion in a stationary gas turbine with the objectives of more efficient engine operation, resulting in significant fuel savings, increased output power, and reduced emissions. The engine selected for the program, the Centaur 50 is being retrofitted with first stage ceramic blades, first stage ceramic nozzles, and a ceramic combustor liner. The engine hot section is being redesigned to accommodate the ceramic parts to the existing metallic support structure. Detailed design of the ceramic components and of the interfacing metallic support structure has been completed. Two blade designs with different attachments and a nozzle design with a modified airfoil geometry have been developed. Three combustor liner designs are being evaluated based on monolithic tiles or rings, or integral cylinders of continuous fiber-reinforced ceramic matrix composites (CFCC). Fabrication of first generation prototype blades and nozzles is in progress. Fabrication of subscale combustor hardware has been completed. Materials property data are being gathered in support of the ceramic component design and life prediction. Fast fracture and dynamic fatigue testing were performed for the candidate blade and nozzle materials. Creep and oxidation testing is in progress. Nondestructive methodologies are being applied to test specimens, simulated components, subscale hardware and prototype components. A Centaur 50 engine was procured and has been modified for ceramic component testing in a full-size engine configuration.

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