CFD Study of Nozzle Configurations for Ultra High Bypass Engines

Performance and aerodynamic aspects of ultra-high bypass ratio ducted engines have been investigated with an emphasis on nozzle aerodynamics. The interference with aircraft aerodynamics could not be covered. Numerical methods were used for aerodynamic investigations of geometrically different aft end configurations for bypass ratios between 12 and 18, this is the optimum range for long missions which will be important for future civil engine applications. Results are presented for a wide range of operating conditions and effects on engine performance are discussed. The limitations for higher bypass ratios than 12 to 18 do not come from nozzle aerodynamics but from installation effects. It is shown that using CFD and performance calculations an improved aerodynamic design can be achieved. Based on existing correlations, for thrust and mass-flow, or using aerodynamic tailoring by CFD and including performance investigations, it is possible to increase the thrust coefficient up to 1%.

Performance Testing and Strength Prediction of Ceramic-to-Metal Joints

Brazed joints were made between silicon nitride and Ni-based and Fe-based super alloys. Room temperature shear (torsion) strengths ranged from 75–242 MPa for Si3N4-to-Incoloy 909 joints and from 30–127 MPa for the Si3N4-to-Inconel 718 joints. At 500 °C the joint strength was 120 MPa while at 650°C and 950°C the joints strengths were less than 20 MPa. These low strengths at 650°C and 950°C were attributed to a reduction in the shrink-fit and to low braze strength at these high temperatures. Finite element analysis (FEA) and a probabilistic failure theory (CARES) were used to predict the joint strengths. The predicted joint strengths agreed well with measured joint strengths in torsional loading at 20°C. Torsion tests were also performed at 650°C. Aspects of the material systems, residual stresses, mechanical behavior, and strength predictions are presented. Two new braze alloys based on the Au-Ni-Cr-Fe system were used to overcome the poor high temperature strength. Joints made with these brazes had good strength (85 MPa and 35 N-m) at 650°C.

Externally-Fired Combined Cycle Repowering of Existing Steam Plants

The Externally-Fired Combined Cycle (EFCC) is an attractive emerging technology for powering high efficiency combined gas and steam turbine cycles with coal or other ash bearing fuels. The key near-term market for the EFCC is likely to be repowering of existing coal fueled power generation units. Repowering with an EFCC system offers utilities the ability to improve efficiency of existing plants by 25 to 60 percent, while doubling generating capacity. Repowering can be accomplished at a capital cost half that of a new facility of similar capacity. Furthermore, the EFCC concept does not require complex chemical processes, and is therefore very compatible with existing utility operating experience. In the EFCC, the heat input to the gas turbine is supplied indirectly through a ceramic heat exchanger. The heat exchanger, coupled with an atmospheric coal combustor and auxiliary components, replaces the conventional gas turbine combustor. Addition of a steam bottoming plant and exhaust cleanup system completes the combined cycle. A conceptual design has been developed for EFCC repowering of an existing reference plant which operates with a 48 MW steam turbine at a net plant efficiency of 25 percent. The repowered plant design uses a General Electric LM6000 gas turbine package in the EFCC power island. Topping the existing steam plant with the coal fueled EFCC improves efficiency to nearly 40 percent. The capital cost of this upgrade is 1,090/kW. When combined with the high efficiency, the low cost of coal, and low operation and maintenance costs, the resulting cost of electricity is competitive for base load generation.

Modeling of Tip Clearance Flows Through an Improved 3-D Pressure Correction Navier-Stokes Solver

Mechanical constraints dictate the existence of tip clearances in rotating cascades, resulting to a flow leakage through this clearance which considerably influences the efficiency and range of operation of the machine. Three-dimensional Navier-Stokes solvers are often used for the numerical study of compressor and turbine stages with tip-clearance. The quality of numerical predictions depends strongly on how accurately the blade tip region is modelled; in this respect the accurate modelling of tip region was one of the main goals of this work. In the present paper, a 3-D Navier-Stokes solver is suitably adapted so that the flat tip surface of a blade and its sharp edges could be accurately modelled, in order to improve the precision of the calculation in the tip region. The adapted code solves the fully elliptic, steady, Navier-Stokes equations through a space-marching algorithm and a pressure correction technique; the H-type topology is retained, even in cases with thick leading edges where a special treatment is introduced herein. The analysis is applied to two different cases, a linear cascade and a compressor rotor, and comparisons with experimental data are provided.

Observations of Wake-Induced Turbulent Spots on an Axial Compressor Blade

Measurements of transitional flow in regions of strong adverse pressure gradient on an axial compressor stator are reported. The range of observations covers separating laminar flow at transition onset, and reattachment of intermittently turbulent periodically separated shear layers. Transition was characterised by the regular appearance of turbulent spots in association with the rotor blade wake disturbances. However, the initial breakdown did not coincide with the wake passage as has usually been observed by other workers. The spots rather evolved from the growth of instability wave packets which lagged the wake passage. Data presented from the compressor blade measurements include: mean and ensemble-average velocities and associated integral parameters; distributions of total, periodic and random disturbance components; typical individual velocity fluctuation records; contours of ensemble-average random disturbance level; and boundary layer intermittency distributions. Measurements of turbulent intermittency showed a significant fall in this quantity near the wall in the reattaching flow. This has significant implications for the interpretation of transition data from surface film gage observations.

Study on the Turbine Vane and Blade for a 1500°C Class Industrial Gas Turbine

This paper describes the summary of a three year development program for the 1st stage stationary vane and rotating blade for the next generation, 1500°C Class, high efficiency gas turbine. In such a high temperature gas turbine, the 1st turbine vane and blade are the most important hot parts. Full coverage film cooling (FCFC) is adopted for the cooling scheme, and directionally solidified (DS) nickel base super-alloy and thermal barrier coating (TBC) will be used to prolong the creep and thermal fatigue life. The concept of the cooling configuration, fundamental cascade test results and material test results will be presented.

Active Stabilization of Rotating Stall in a Three-Stage Axial Compressor

A three-stage, low speed axial research compressor has been actively stabilized by damping low amplitude circumferentially travelling waves which can grow into rotating stall. Using a circumferential array of hot wire sensors, and an array of high speed individually positioned control vanes as the actuator, the first and second spatial harmonics of the compressor were stabilized down to a characteristic slope of 0.9, yielding an 8% increase in operating flow range. Stabilization of the third spatial harmonic did not alter the stalling flow coefficient. The actuators were also used open loop to determine the forced response behavior of the compressor. A system identification procedure applied to the forced response data then yielded the compressor transfer function. The Moore-Greitzer, 2-D, stability model was modified as suggested by the measurements to include the effect of blade row time lags on the compressor dynamics. This modified Moore-Greitzer model was then used to predict both the open and closed loop dynamic response of the compressor. The model predictions agreed closely with the experimental results. In particular, the model predicted both the mass flow at stall without control and the design parameters needed by, and the range extension realized from, active control.

Transonic Compressor Rotor Cascade With Boundary-Layer Separation: Experimental and Theoretical Results

A transonic compressor rotor cascade designed for an inlet Mach number of 1.09 and 14 degrees of flow turning has been redesigned for higher loading by an increased pitch-to-chord ratio. Test results, showing the influence of inlet Mach number and flow angle on cascade performance are presented and compared to data of the basic design. Loss-levels of both, the original and the redesigned higher loaded blade were identical at design condition, but the new design achieved even lower losses at lower inlet Mach numbers. The computational design and analysis has been performed by a fast inviscid time-dependent code coupled to a viscous direct/inverse integral boundary-layer code. Good agreement was achieved between measured and predicted surface Mach number distributions as well as exit-flow angles. A boundary-layer visualization method has been used to detect laminar separation bubbles and turbulent separation regions. Quantitative results of measured bubble positions are presented and compared to calculated results.

Finite Element Analysis of Two-Dimensional Turbulent Asymmetric Near and Far Non-Periodic and Periodic Wakes by κ-ϵ Model of Turbulence

Two dimensional time averaged, steady incompressible, adiabatic turbulent asymmetric near and far non-periodic and periodic wake flow problems are solved by Galerkin Finite Element Method. A primitive-variables formulation is adopted using Reynolds-averaged momentum equations, with standard k-ε turbulence model. Finite element equations are solved by Newton-Raphson technique with relaxation, using frontal solver. Periodic boundary condition is specified on the periodic lines of the cascade, and asymptotic boundary condition is specified at the exit. These boundary conditions are applied without much difficulty which are not so straight forward in finite volume (FV) method. The results show good agreement with FV prediction and experimental data.

The Marshall Space Flight Center Turbine Test Equipment: Description and Performance

Performance evaluations of rocket engine turbopump drive turbines are difficult to obtain from turbopump or engine firings due to measurement limitations and operating point restrictions. The Marshall Space Flight Center (MSFC) Turbine Test Equipment (TTE) was developed to provide an accurate, economical method of measuring the performance of full-scale turbopump gas turbines. By expanding air at pressures as high as 435 psia (3.0 MPa) to atmospheric conditions, the TTE provides metered air at nominal conditions of 100 psia (0.69 MPa), 550 °R (350 °K), and 15 lbm/sec (6.8 kg/sec) with run times of 100 seconds or greater. A 600 hp (448 kW) direct current dynamometer and gearbox provide turbine power absorption for speeds up to 14,000 rpm. This paper describes the MSFC TTE and its performance including the performance envelope, turbine inlet flow quality, and measurement uncertainty.