Engine Test Experience and Characterization of Self Sealing Ceramic Matrix Composites for Nozzle Applications in Gas Turbine Engines

Advanced materials are targeting durability improvement in gas turbine engines. One general area of concern for durability is in the hot section components of the engine. Ceramic matrix composites offer improvements in durability at elevated temperatures with a corresponding reduction in weight for nozzles of gas turbine engines. Building on past material efforts, ceramic matrix composites using a carbon and a SiC fiber with a self-sealing matrix have been developed for gas turbine applications. Prior to ground engine testing, a reduced test matrix was undertaken to aggressively test the material in a long-term hold cycle at elevated temperatures and environments. This tensile low cycle fatigue testing was done in air and a 90% steam environment. After completion of the aggressive testing effort, six nozzle seals were fabricated and installed in an F100-PW-229 engine for accelerated mission testing. The C fiber CMC and the SiC Fiber CMC were respectively tested to 600 and 1000 hours in accelerated conditions without damage. Engine testing is continuing to gain additional time and insight with the objective of pursuing the next phase of field service evaluation. Mechanical testing and post-test characterization results of this testing will be presented. The results of the engine testing will be shown and overall conclusions drawn.

Gas Turbine Simulations in the Computerized Educational Program CompEduHPT: Educational Aspects

In the winter 1813–1814 I attended a mathematical school kept in Boston ... on entering his room, we were struck at the appearance of an ample Blackboard suspended on the wall, with lumps of chalk on a the ledge below, and cloths hanging at either side. I never heard such a thing before. The introduction of computerized presentation techniques and overheads has also changed the teaching process as the blackboard did it on the 19th century. Computerized techniques have made possible showing the students more material related with the specific subject. Special videos, simulations and other multimedia tools represent one of the most relevant changes in the traditional learning. Simulations enable the students to familiarize themselves with the topic and highlight the key parameters as well as their influence. Several simulations have been included in the Computerized Educational Platform (CompEduHPT) together with theory and other educational features. These simulations constitute an alternative way to learn, based on discovery and experience. It is important to realize that the simulations are only a part of the package of learning. All the simulations are preceded with theory chapters, quizzes and preparatory tasks to enable fruitful exercises to be designed, including the simulations. Furthermore, the majority of these simulations are supported by a “guide” that provides help advising the student on how to perform the simulation and inviting him/her to analyze the changes every time that the student clicks on it based on the theory given in the chapters. This creates a completely integrated educational tool designed to enhance the learning of students involved in gas turbine technology courses either at the campus or as distant learners. A variety of simulations exist, stretching from simulated basic physical phenomena to complete cycle simulations. The Gas Turbine related simulations comprise for example a number of ideal and real gas turbine cycles, basic two-dimensional velocity triangle simulations as well as aerodynamic design of turbomachines and aeroelasticity simulations. One of the objectives of this paper is to show the potential of integrating the simulations in the learning process and the possible ways to overcome some of the obstacles by using tools already available and designed to enhance the learning process such as CompEduHPT. Evaluations show that simulations are appreciated among the students as an aid to grasp the general physical understanding of formulas and theory enhancing the learning process. The learning method and learning pace are highly valued among the students, which indicates that a computerized program including multiple ways of learning may be of considerable support to the more conventional and personal student-teacher way of learning.

Comparison of Linear and Non-Linear Gas Turbine Performance Diagnostics

The features of linear performance diagnostic methods are discussed, in comparison to methods based on full non-linear calculation of performance deviations, for the purpose of condition monitoring and diagnostics. First, the theoretical background of linear methods is overviewed to establish a relationship to the principles used by non-linear methods. Then computational procedures are discussed and compared. The effectiveness of determining component performance deviations by the two types of approaches is examined, on different types of diagnostic situations. A way of establishing criteria to define whether non-linear methods have to be employed is presented. An overall assessment of merits or weaknesses of the two types of methods is attempted, based on the results presented in the paper.

High Temperature Hydro Corrosion Resistance of Silica Based Oxide Ceramics

Water vapor corrosion behavior of Ln2Si2O7 (Ln = Nd, Er, Lu), mullite, CaYb4Si3O13 and Al2O3 were investigated at 1500°C. In Ln2Si2O7 phases, Ln = Nd and Er samples were completely dissolved in water vapor environment. CaYb4Si3O13 phase underwent decomposition during the corrosion test. Lu2Si2O7 and mullite showed excellent water vapor corrosion protection. In the case of mullite, Al2O3 rich phase was formed on the surface and the corrosion progression was successfully protected. In the case of Lu2Si2O7 phase, phase transition occurred and the grain boundaries of surface layer were slightly corroded by the corrosion test.

Optimum Gain-Scheduling PID Controllers for Gas Turbine Engines Based on NARMAX and Neural Network Models

This paper presents PID controller designs based on NARMAX and feedforward neural network models of a Spey gas turbine engine. Both models represent the dynamic relationship between the fuel flow and shaft speed. Due to the engine non-linearity, a single set of PID controller parameters is not sufficient to control the gas turbine throughout the operating range. Gain-scheduling PID controllers are therefore used in order to obtain optimum control. A comparison between the controller designs based on the two model representations is also made.

Temperature Measurement System for Low Pressure Ratio Turbine Testing

In 1999, ITP (Industria de Turbopropulsores, S.A.) launched a wide on-going research program focusing on new technologies to provide significant improvements in Low Pressure Turbines cost and weight. As consequence of the new technologies the experience limits are exceeded and new unknown concepts, like high stage loading turbines, must be explored and then a wide experimental work is required for validation purposes. Cold flow single stage rigs in high-speed facilities were selected by ITP as main vehicle to carry out the experimental validation. Single stage Low Pressure Turbine rigs have low-pressure ratio and power consumption, therefore efficiency predictions based on temperature drop require high accuracy thermocouple measurement systems (precision uncertainties lower than ±50 mK), if small efficiency variations must be captured. In this paper, a detailed uncertainty analysis is introduced and a temperature measurement system that allows achieving such high measurement accuracy is evaluated and described. Type T thermocouples are proposed for use in the range 0°C to 80°C, which are individually calibrated. The procedure followed for this calibration is presented and how is possible to achieve a precision of 30 mK. It is also shown as conventional UTR based on metal plates can behave as good as thermal baths in terms of temperature uniformity and errors, with the adequate isolation and temperature reference calibration. The conventional data recording and voltage measurement systems are experimentally evaluated, and they are found as main source of temperature errors. Although following some recommendations the precision of those systems can be improved, it is experimentally probed and therefore suggested the use of high accuracy voltmeter with a commutation unit to reduce significantly the temperature uncertainty. Finally a miniature Kiel Shroud is proposed and aerodynamically characterised in a high-speed facility. Mach, Reynolds number, yaw, blockage and manufacturing tolerance impact on recovery factor can be inferred from those results.

Dual Wavelength Temperature Monitoring of TBC Coated Alstom 13E2 Turbine Blades

Through rapid developments in fiber technology and data acquisition technology, pyrometry has become a successful tool for the measurement of gas turbine blade temperatures. The technology enables gas turbine owners and operators to monitor the blades and to optimise the exploitation of their assets in terms of efficiency and maintenance. With the application of thermal barrier coatings on turbine blades, pyrometry faces a new challenge as these coatings are not opaque at commonly used wavelengths. The application of TBC’s to protect the metal blades allows an increase of the firing temperature, increasing the efficiency of the installation, but is potentially an additional cause of locally overheating blades in the case the coating comes off. The present paper reports on the results of experimental work related to the temperature measurement on an in service Alstom 13E2 turbine with TBC coated first stage blades. Temperature measurements have been performed with both short- and long wavelength instruments (1 μm and 10 μm). The optical characteristics of ZrO2 material at a range of temperatures have been determined. These characteristics are important in the implementation of an algorithm that calculates the metal temperature from the temperature measurement results. These metal temperatures are of primary interest, This is the first time that experimental radiation temperature measurements on an industrial turbine, using both 1 and 10 μm technology, are reported. As the measurement trace over the turbine airfoil consists of areas on the blade that are covered with TBC as well as uncovered areas, a very interesting comparison on the merits of the various systems can be presented.

Validation of a Mixed Flow Turbofan Performance Model in the Sub-Idle Operating Range

During turbofan development programs the evaluation of steady-state and transient engine performance is usually achieved by applying full thermodynamic engine models at least in the operating range between idle and maximum power conditions, but more recently also in the sub-idle operating range, e.g. for steady-state windmilling behavior and for starting, relight and shut down scenarios. The paper describes the setup, and in more detail the validation, of a full thermodynamic engine model for a two-spool mixed flow afterburner turbofan which is capable to run from maximum power down to zero speed and zero flow conditions in steady-state and transient mode. The validation is performed by using the model-based performance analysis procedure called ANSYN even in windmilling operation. Once the steady-state sub-idle model is validated the extension to transient sub-idle capability is achieved by simply adding the effects of rotor moment of inertia of the spools, while heat soakage effects are rather negligible without heat release in the burner. Especially lighting conditions in the burner are produced by such a validated sub-idle model inherently due to reliable data calculated at the burner entry station. The variety of applications of a validated full thermodynamic engine model is large. The performance data delivered is highly reliable and very consistent because the full operating range of the engine is covered with one model, and by appropriate means of speeding up the calculation even real-time capability may be achieved. In the paper synthesized data for an engine dry crank is compared to real engine test data as one typical application.

Exo-Skeletal Engine: Novel Engine Concept

The Exo-Skeletal Engine concept represents a new radical engine technology with the potential for a substantial revolution in engine design. It is an all composite drum rotor engine in which conventional heavy shafts and discs are eliminated and are replaced by rotating casings that support the blades in spanwise compression. Thus the rotating blades are in compression rather than in tension. The resulting open channel at the engine centerline has immense potential for jet noise reduction, and can also accommodate an inner combined-cycle thruster such as a ramjet. The Exo-Skeletal Engine is described in some detail with respect to geometry, components and potential benefits. Initial evaluation, results for drum rotors, bearings and weights are summarized. Component configuration, assembly plan and potential fabrication processes are also identified. A finite element model of the assembled engine and its major components are described. Preliminary results obtained thus far show at least 30 percent reduction of engine weight and about 10 db noise reduction, compared to a baseline conventional high bypass-ratio engine. Potential benefits in all aspects of engine technology are identified and tabulated. Quantitative assessments of potential benefits are in progress.

A Multi-Component and Multi-Disciplinary Student Design Project Within an International Academic and Industrial Collaboration

The design of modern aircraft engines increasingly involves highly sophisticated methodologies to match the current development pace. International company relations affect the collaboration between design offices all around the world. An important part of academic mission of modern engineering education is to produce graduates with skills compatible with industrial needs. Education may readjust accordingly to meet the higher requirements. However, a realistic scenario of the design process of an aircraft engine cannot possibly be transferred one-to-one into the student education process. A unique attempt to overcome this discrepancy was the International Gas Turbine Project. Within this project, undergraduate students have designed the cooling system of the HPT blades for a 30,000 lb thrust two-spool turbofan aeroengine. This project was collaboration between the Jet Propulsion Laboratory of TU Berlin, the Turbomachinery Group of EC Lyon and the Turbomachinery Laboratory of ETH Zurich. It also involved mentoring industry professionals from Rolls-Royce Deutschland, MTU, SNECMA and Alstom Power. Similar to modern aeroengine company structures, the design tasks included multi-component, multi-disciplinary and international interfaces of different educational systems. The student teams considered various aerothermodynamic and mechanical integrity aspects of the design. Particular attention was paid to design of the compressor, the secondary air system and the HP turbine including blade cooling. The three Universities integrated the project differently into their education curriculum and approached the tasks with different levels of software involvement. In this paper, the technical details of the design process, and the different approaches adopted are presented. Besides the application of turbomachinery-related knowledge, the impact of student interactions on the technical aspects of the project is discussed. The interfaces, including information management and the involvement of industrial partners are also addressed. Team spirit developed between the students from an initial competitive behavior to a final feeling of sitting in the same boat. It was observed that increased effort was required from academic staff in comparison to the conventional academic instruction. Nevertheless, students greatly benefited from the social interaction and an early training-on-the-job tuned to current industrial needs.