Engineering topics
Ghoshal, Anindya
Publications and source records attributed to Ghoshal, Anindya.
High Temperature Ceramic Microstructure and Interface Evolution during Exposure to Particulate Laden Combustion Flows in Gas Turbine Engines
Objective: To innovate sandphobic coating and surface modification for high temperature turbine blades to resist sand glaze build-up and related Calcia-Magnesia-Alumina-Silicate (CMAS) attack on Thermal/Environmental Barrier Coatings (T/EBCs).
Microstructure Based Material-Sand Particulate Interactions and Assessment of Coatings for High Temperature Turbine Blades
Gas turbine engines for military/commercial fixed-wing and rotary wing aircraft use thermal barrier coatings in the high-temperature sections of the engine for improved efficiency and power. The desire to further make improvements in gas turbine engine efficiency and high power-density is driving the research and development of thermal barrier coatings and the effort of improving their tolerance to fine foreign particulates that may be contained in the intake air. Both commercial and military aircraft engines often are required to operate over sandy regions such as in the Middle-East nations, as well as over volcanic zones. For rotorcraft gas turbine engines, the sand ingestion is adverse during take-off, hovering near ground, and landing conditions. Although, most of the rotorcraft gas turbine engines are fitted with inlet particle separators, they are not 100 percent efficient in filtering fine sand particles of size 75 microns or below. The presence of these fine solid particles in the working fluid medium has an adverse effect on the durability of turbine blade thermal barrier coatings and overall performance of the engine. Typical turbine blade damages include blade coating wear, sand glazing, Calcia-Magnesia-Alumina-Silicate (CMAS) attack, oxidation, plugged cooling holes, all of which can cause rapid performance deterioration including loss of aircraft. The objective of this research is to understand the fine particle interactions with typical ceramic coatings of turbine blades at the microstructure level. A finite-element based microstructure modeling and analysis has been performed to investigate particle-surface interactions, and restitution characteristics. Experimentally, a set of tailored thermal barrier coatings and surface treatments were down-selected through hot burner rig tests and then applied to first stage nozzle vanes of the Gas Generator Turbine of a typical rotorcraft gas turbine engine. Laser Doppler velocity measurements were performed during hot burner rig testing to determine sand particle incoming velocities and their rebound characteristics upon impact on coated material targets. Further, engine sand ingestion tests were carried out to test the CMAS tolerance of the coated nozzle vanes. The findings from this on-going collaborative research to develop the next-gen sand tolerant coatings for turbine blades are presented in this paper.
Thermochemistry of Calcium-Magnesium-Aluminum-Silicate (CMAS) and Components of Advanced Thermal and Environmental Barrier Coating Systems
There is increasing interest in the degradation mechanism studies of thermal and environmental barrier coatings (TEBCs) of gas turbines by molten CaO-MgO-Al(exp. 2)O(exp. 3)-SiO(exp. 2) CMAS). CMAS minerals are usually referred as silicon-containing sand dust and volcano ash materials that are carried by the intake air into gas turbines, e.g. in aircraft engines, and their deposits often react at high temperatures (greater than 1200 degrees C) with the engine turbine coating systems and components. The high temperature reactions causes degradation and accelerated failure of the static and rotating components of the turbine engines. We discuss some results of the reactions between the CMAS and Rare-Earth (RE = Y, Yb, Dy, Gd, Nd and Sm) - oxide stabilized ZrO(exp. 2) or HfO(exp. 2) systems, and the stability of the resulting oxides and silicates. Plasma sprayed hollow tube samples (outside diameter = 4.7 mm, wall thickness = 0.76 mm and = 26 mm height) were half filled with CMAS powder, wrapped and sealed with platinum foil, and heat treated at 1310 degrees C for 5h. Samples were characterized by differential scanning calorimetry (DSC), X-ray diffraction, and cross-section electron microscopy analysis and energy dispersive X-ray spectroscopy. It was found that CMAS penetrated the samples at the grain boundaries and dissolved the TEBC materials to form silicate phases containing the rare-earth elements. Furthermore, it was found that apatite crystalline phases were formed in the samples with total rare-earth content higher than 12 mol% in the reaction zone for the ZrO(exp. 2) system. In general, samples with the nominal compositions (30YSZ), HfO(exp. 2)-7Dy(exp. 2)O(exp. 2) and ZrO(exp. 2)-9.5Y(exp. 2)O(exp. 3)-2.25Gd(exp. 2)O(exp. 3)-2.25Yb(exp. 2)O(exp. 3) exhibited lower reactivity or more resistance to CMAS than the other coating compositions of this work.
Comparative Study of Vibration Condition Indicators for Detecting Cracks in Spur Gears
This paper reports the results of an empirical study on the tooth breakage failure mode in spur gears. Of four dominant gear failure modes (breakage, wear, pitting, and scoring), tooth breakage is the most precipitous and often leads to catastrophic failures. The cracks were initiated using a fatigue tester and a custom-designed single-tooth bending fixture to simulate over-load conditions, instead of traditional notching using wire electrical discharge machining (EDM). The cracks were then propagated on a dynamometer. The ground truth of damage level during crack propagation was monitored with crack-propagation sensors. Ten crack propagations have been performed to compare the existing condition indicators (CIs) with respect to their: ability to detect a crack, ability to assess the damage, and sensitivity to sensor placement. Of more than thirty computed CIs, this paper compares five commonly used: raw RMS, FM0, NA4, raw kurtosis, and NP4. The performance of combined CIs was also investigated, using linear, logistic, and boosted regression trees based feature fusion.
Concepts and Development of Bio-Inspired Distributed Embedded Wired/Wireless Sensor Array Architectures for Acoustic Wave Sensing in Integrated Aerospace Vehicles
This paper discusses the modeling of acoustic emissions in plate structures and their sensing by embedded or surface bonded piezoelectric sensor arrays. Three different modeling efforts for acoustic emission (AE) wave generation and propagation are discussed briefly along with their advantages and disadvantages. Continuous sensors placed at right angles on a plate are being discussed as a new approach to measure and locate the source of acoustic waves. Evolutionary novel signal processing algorithms and bio-inspired distributed sensor array systems are used on large structures and integrated aerospace vehicles for AE source localization and preliminary results are presented. These systems allow for a great reduction in the amount of data that needs to be processed and also reduce the chances of false alarms from ambient noises. It is envisioned that these biomimetic sensor arrays and signal processing techniques will be useful for both wireless and wired sensor arrays for real time health monitoring of large integrated aerospace vehicles and earth fixed civil structures. The sensor array architectures can also be used with other types of sensors and for other applications.
Active Wave Propagation and Sensing in Plates
Health monitoring of aerospace structures can be done using an active interrogation approach with diagnostic Lamb waves. Piezoelectric patches are often used to generate the waves, and it is helpful to understand how these waves propagate through a structure. To give a basic understanding of the actual physical process of wave propagation, a model is developed to simulate asymmetric wave propagation in a panel and to produce a movie of the wave motion. The waves can be generated using piezoceramic patches of any size or shape. The propagation, reflection, and interference of the waves are represented in the model. Measuring the wave propagation is the second important aspect of damage detection. Continuous sensors are useful for measuring waves because of the distributed nature of the sensor and the wave. Two sensor designs are modeled, and their effectiveness in measuring acoustic waves is studied. The simulation model developed is useful to understand wave propagation and to optimize the type of sensors that might be used for health monitoring of plate-like structures.