Development of New High AN2 Last LP Stage Turbine and Exhaust Systems: A Cost Effective Solution for the 21st Century
A new high AN2 last LP stage turbine has been developed to provide leading performance for turbomachines in the 21st Century. It required a multi-disciplinary design approach involving aerodynamics, materials, mechanics (stress and vibration) and manufacturing technologies. The objective of the design was to achieve around 5% gain in last stage total-to-static efficiency, relative to the current competitive datum, for a very compact machine with few parts count ie reduced cost. It is shown how the optimum aerodynamic design was achieved for the stage. The paper presents details of the novel approaches used for the design including preliminary optimization, blading design and results from multistage 3D viscous predictions. The new stage has been tested in a Warm Air Turbine test rig at full scale engine representative conditions. The “loop was closed” by comparing the detailed test measurements with throughflow and 3D viscous analyses. This gives high confidence in the new approaches used. Additionally, the development of new compact high performance axial-radial and axial exhaust systems, which were designed to operate downstream of the new last LP stage, are described. To achieve the optimum performance, the last LP stage has to designed as a coupled system with the exhaust diffusers. The new LP technologies have already been scaled and cloned to a new engine design and sold by the Company.