Engineering topics
Publications and source records attributed to Calfo, F. D..
Micronized-coal (coal-in-oil mix) burner facility developed to fulfill need to generate erosion/corrosion data on series of superalloy specimens. In order to successfully operate gas turbine using COM, two primary conditions must be met. First, there must be adequate atomization of COM and second, minimization of coking of burner. Meeting these conditions will be achieved only by clean burning and flame stability.
A facility was constructed to provide relatively low cost testing of hot section turbine blade and vane materials under hot corrosion conditions more akin to service environments. The facility consists of a small combustor whose pressurized gas flow can be directed to either a test section consisting of three small cascaded specimens or to a partial admittance single-stage axial flow turbine. The turbine rotor contains 28 replaceable turbine blades. The combustion gases resulting from the burning of Jet A-l fuel can be seeded with measured amounts of alkali salts. This facility is described here along with preliminary corrosion test results obtained during the final checkout of the facility.
A combustor or burner system in which the ash resulting from burning a coal in oil mixture is of submicron particle size is described. The burner system comprises a burner section, a flame exit nozzle, a fuel nozzle section, and an air tube by which preheated air is directed into the burner section. Regulated air pressure is delivered to a fuel nozzle. Means are provided for directing a mixture of coal particles and oil from a drum to a nozzle at a desired rate and pressure while means returns excess fuel to the fuel drum. Means provide for stable fuel pressure supply from the fuel pump to the fuel nozzle.
Wedge shaped specimens were exposed to the combustion gases of a Mach 0.3 burner rig fueled with a mixture of 40 weight percent micron size coal particles dispersed in No. 2 fuel oil. Exposure temperature was about 900 C and the test duration was about 44 one hour cycles. The alloys tested were the nickel base superalloys, IN-100, U-700 and IN-792, and the cobalt base superalloy, Mar-M509. The deposits on the specimens were analyzed and the extent of corrosion/erosion was measured. The chemical compositions of the deposits were compared with the predictions from an equilibrium thermodynamic analysis. The experimental results were in very good agreement with the predictions.
Electro-optical extensometer containing optical and electronic components measures displacement in simulated turbine blade thermally cycled into and out of hot-gas stream. Innovation is useful in obtaining accurate strain histories for components subjected to severe thermal environments and other environmental changes.
The effect of off-axis directionally solidified (DS) grain growth on thermal fatigue life of Mar-M 247 alloy was evaluated. Uncoated conventionally cast as well as DS wedge bars were cycled in a burner rig between 1070 C and room temperature. The longitudinal axis and leading edge of the specimen coincided. As the angle between the specimen longitudinal axis and growth axis increased, the thermal fatigue life decreased for both the uncoated and aluminide-coated bars. Life increases of about 50 cycles for the DS conditions were attributed to coating. The decrease in thermal fatigue life with increasing angle is primarily attributed to the increase in modulus of elasticity with increasing angle and not to the intersection of DS grain boundaries with the specimen leading edge. The thermal fatigue cracks were observed to be transgranular in the DS material. Limited tensile and stress-rupture properties of conventionally cast and off-axis DS Mar-M 247 alloy are also presented.
Noncontacting techniques were used to measure strain and temperature in thermally cycled simulated turbine blades. An electro-optical extensometer was used to measure the displacement between parallel targets mounted on the leading edge of the blades throughout a complete heating and cooling cycle. An infrared photographic pyrometry method was used to measure blade steady state surface temperature. The blade was cyclically heated and cooled by moving it into and out of a Mach 1 hot-gas stream. Transient leading edge strain and steady state surface temperature distributions are presented for blades of three different configurations.
A type of noncontacting electro-optical extensometer was used to measure the displacement between parallel targets mounted on the leading edge of a simulated turbine blade throughout a complete heating and cooling cycle. The blade was cyclically heated and cooled by moving it into and out of a Mach 1 hot gas stream. The principle of operation and measurement procedure of the electro-optics extensometer are described.
The effect of radiant(furnace), resistance(electric current), burner(hot gas stream), and a combination of resistance and burner heating on intermediate time (100 to 300 hr) stress-rupture life and reduction of area was evaluated. All heating methods were studied using the nickel-based alloy Udimet 700 while all but burner heating were evaluated with the cobalt-based alloy Mar-M 509. Limited test results of eight other superalloys were also included in this study. Resistance heated specimens had about 20 to 30 percent of the stress-rupture life of radiant heated specimens. The limited burner heating data showed about a 50 percent life reduction as compared to the radiant heated tests. A metallurgical examination gave no explanation for these reductions.
Simulated turbine blade thermal fatigue testing under transient and steady state heating and spanwise loading, obtaining crack initiation and propagation data
Fracture mechanics theory used to determine effects of crack dimensions and material properties on fracture stresses for thin metal sections with through and part-through cracks
Burner rig tests on simulated turbine blades, with and without internal cooling, to predict thermal fatigue performance
Ti-Al-Sn and Al alloys thin sectioned specimens cryogenic fracture strength, discussing surface crack fracture behavior
Metal surface through and part through cracks, investigating dimensions and material properties effects on fracture stresses
Cryogenic fracture properties of thin AISI 301 cold reduced sheet at different angles to rolling direction
Residual stress effects on fracture strength of AISI 301 stainless steel and Ti-5Al-2.5Sn titanium cracked thin walled cylinders