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Criteria for the design and development of turbines for rocket engines to meet specific performance, and installation requirements are summarized. The total design problem, and design elements are identified, and the current technology pertaining to these elements is described. Recommended practices for achieving a successful design are included.
The potential role of superalloys, refractory alloys, and ceramics in the hottest sections of engines operating with turbine inlet temperatures as high as 1370 C is examined. The convential superalloys, directionally solidified eutectics, oxide dispersion strenghened alloys, and tungsten fiber reinforced superalloys are reviewed and compared on the basis of maximum turbine blade temperature capability. Improved high temperature protective coatings and special fabrication techniques for these advanced alloys are discussed. Chromium, columbium, molybdenum, tantalum, and tungsten alloys are also reviewed. Molbdenum alloys are found to be the most suitable for mass produced turbine wheels. Various forms and fabrication processes for silicon nitride, silicon carbide, and SIALON's are investigated for use in highstress and medium stress high temperature environments.
Convertible engine aircraft gas-turbine is two engines in one. Produces turbofan thrust, turboshaft power, or any combined thrust and shaftpower continously while operating up to full speed. Used to power vertical/short-takeoff-and-landing (V/STOL) airplanes and advanced high-speed rotorcraft. Rotorcraft shows use of convertible engines rather than separate engines for rotor power and forward thrust affords advantages in installation and save 16 percent in fuel and 20 percent in direct operating costs. Engine used for propulsion of new high-speed rotorcraft that needs both thrust and shaft power. Also used to cross-couple fans of two-engine V/STOL aircraft.
An overview is given of advanced concepts for the suppression of noise in the inlets of gas turbine engines. Inlet geometric and operating parameters are presented and design criteria for suppression methods are discussed. Noise suppression concepts are described, the directions of current research are reviewed. Problem areas requiring further work are indicated. Well established approaches to inlet noise reduction - namely, acoustic liners and high subsonic Mach number inlets which are the focus of considerable current research activity are considered along with the acoustic absorption and watet vapor injection.
An overview of four independent studies forecasts the potential impact of advanced technology turbine engines in the post 1988 market, identifies important aircraft and missions, desirable engine sizes, engine performance, and cost goals. Parametric evaluations of various engine cycles, configurations, design features, and advanced technology elements defined baseline conceptual engines for each of the important missions identified by the market analysis. Both fixed-wing and helicopter aircraft, and turboshaft, turboprop, and turbofan engines were considered. Sizable performance gains (e.g., 20% SFC decrease), and large engine cost reductions of sufficient magnitude are predicted to challenge the reciprocating engine in the 300-500 SHP class.
coating combinations were developed for compliant surface bearings and journals to be used in an automotive gas turbine engine. The coatings were able to withstand the sliding start/stops during rotor liftoff and touchdown and occasional short time, high speed rubs under representative loading of the engine. Some dozen coating variations of CdO-graphite, Cr2O3 (by sputtering) and CaF2 (plasma sprayed) were identified. The coatings were optimized and they were examined for stoichiometry, metallurgical condition, and adhesion. Sputtered Cr2O3 was most adherent when optimum parameters were used and it was applied on an annealed (soft) substrate. Metallic binders and interlayers were used to improve the ductility and the adherence.
High speed minicomputers were used in the past to implement advanced digital control algorithms for turbine engines. These minicomputers are typically large and expensive. It is desirable for a number of reasons to use microprocessor-based systems for future controls research. They are relatively compact, inexpensive, and are representative of the hardware that would be used for actual engine-mounted controls. The Control, Interface, and Monitoring Unit (CIM) contains a microprocessor-based controls computer, necessary interface hardware and a system to monitor while it is running an engine. It is presently being used to evaluate an advanced turbofan engine control algorithm.
An analysis of gas turbine engines using water and oxygen injection to enhance performance by increasing Mach number capability and by increasing thrust is described. The liquids are injected, either separately or together, into the subsonic diffuser ahead of the engine compressor. A turbojet engine and a mixed-flow turbofan engine (MFTF) are examined, and in pursuit of maximum thrust, both engines are fitted with afterburners. The results indicate that water injection alone can extend the performance envelope of both engine types by one and one-half Mach numbers at which point water-air ratios reach 17 or 18 percent and liquid specific impulse is reduced to some 390 to 470 seconds, a level about equal to the impulse of a high energy rocket engine. The envelope can be further extended, but only with increasing sacrifices in liquid specific impulse. Oxygen-airflow ratios as high as 15 percent were investigated for increasing thrust. Using 15 percent oxygen in combination with water injection at high supersonic Mach numbers resulted in thrust augmentation as high as 76 percent without any significant decrease in liquid specific impulse. The stoichiometric afterburner exit temperature increased with increasing oxygen flow, reaching 4822 deg R in the turbojet engine at a Mach number of 3.5. At the transonic Mach number of 0.95 where no water injection is needed, an oxygen-air ratio of 15 percent increased thrust by some 55 percent in both engines, along with a decrease in liquid specific impulse of 62 percent. Afterburner temperature was approximately 4700 deg R at this high thrust condition. Water and/or oxygen injection are simple and straightforward strategies to improve engine performance and they will add little to engine weight. However, if large Mach number and thrust increases are required, liquid flows become significant, so that operation at these conditions will necessarily be of short duration.
A mixer assembly for a gas turbine engine is provided, including a main mixer, and a pilot mixer having an annular housing in which a corner is formed between an aft portion of the housing and a bulkhead wall in which a corner recirculation zone is located to stabilize and anchor the flame of the pilot mixer. The pilot mixer can further include features to cool the annular housing, including in the area of the corner recirculation zone.
Ceramic thermal and environmental barrier coatings (TEBC) for SiC-based ceramics will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating long-term durability remains a major concern with the ever-increasing temperature, strength and stability requirements in engine high heat-flux combustion environments, especially for highly-loaded rotating turbine components. Advanced TEBC systems, including nano-composite based HfO2-aluminosilicate and rare earth silicate coatings are being developed and tested for higher temperature capable SiC/SiC ceramic matrix composite (CMC) turbine blade applications. This paper will emphasize coating composite and multilayer design approach and the resulting performance and durability in simulated engine high heat-flux, high stress and high pressure combustion environments. The advances in the environmental barrier coating development showed promise for future rotating CMC blade applications.
The thermal barrier coating used was a yttria stabilized zirconia material with a NiCrAlY undercoat, and the base engine used to establish improvements was the P&WA FT50A-4 industrial gas turbine engine. The design benefits of thermal barrier coatings include simplified cooling schemes and the use of conventional alloys in the engine hot section. Cooling flow reductions and improved heating rates achieved with thermal barrier coating result in improved performance. Economic benefits include reduced power production costs and reduced fuel consumption. Over the 30,000 hour life of the thermal barrier coated parts, fuel savings equivalent to $5 million are projected and specific power (megawatts/mass of engine airflow) improvements on the order of 13% are estimated.
A systematic approach to the use of nondestructive evaluation (NDE) throughout the ceramic engine component development cycle is necessary to achieve the high reliability required for turbine engine applications. Specifically, NDE techniques must be developed and applied to component design, development, fabrication, and test to ensure adequate materials characterization. This approach has the potential of reducing ceramic component cost by optimizing the initial design and eliminating unacceptable components early in the fabrication cycle. Although research NDE techniques have been developed that have the potential to solve the problems of ceramic component inspection, systematic application of these NDE techniques for inspection and process control has not yet occurred. The application of NDE techniques for both material characterization and flaw detection is discussed as well as an approach for applying NDE throughout the fabrication process to achieve highly reliable ceramic components.
This paper describes several alternative approaches, provided by multiplane-multispeed balancing, to traditional gas turbine engine manufacture and assembly procedures. These alternatives, which range from addition of trim-balancing at the end of the traditional assembly process to modular design of the rotating system for assembly and balancing external to the engine, require attention by the engine designer as an integral part of the design process. Since multiplane-multispeed balancing may be incorporated at one or more of several points during manufacture-assembly, its deliberate use is expected to provide significant cost and performance (reduced vibration) benefits. Moreover, its availability provides the designer with a firm base from which he may advance, with reasonable assurance of success, into the flexible rotor dynamic regime.
This paper presents an overview of advanced concepts for the suppression of noise in the inlets of gas turbine engines. Noise suppression concepts are described, the directions of current research are reviewed, and problem areas requiring further work are indicated. The discussion focuses on acoustic liners, high Mach number inlets, active acoustic absorption, water vapor injection, and blade row reflection.
Material coatings for an air-lubricated, compliant journal bearing for an automotive gas turbine engine were exposed to service test temperatures of 540 C or 650 C for 300 hours, and to 10 temperature cycles from room temperatures to the service test temperatures. Selected coatings were then put on journal and partial-arc foils and tested in start-stop cycle tests at 14 kPa (2 psi) loading for 2000 cycles. Half of the test cycles were performed at a test chamber service temperature of 540 C (1000 F) or 650 C (1200 F); the other half were performed at room temperature. Based on test results, the following combinations and their service temperature limitations are recommended: HL-800 TM (CdO and graphite) on foil versus chrome carbide on journal up to 370 C (700 F); NASA PS 120 (Tribaloy 400, silver and CaF2 on journal versus uncoated foil up to 540 C (1000 F); and Kaman DES on journal and foil up to 640 C (1200 F). Kaman DES coating system was further tested successfully at 35 kPa (5 psi) loading for 2000 start-stop cycles.
Current ceramic materials, component fabrication processes, and reliability prediction capability for ceramic stators in an automotive gas turbine engine environment are assessed. Simulated engine duty cycle testing of stators conducted at temperatures up to 1093 C is discussed. Materials evaluated are SiC and Si3N4 fabricated from two near-net-shape processes: slip casting and injection molding. Stators for durability cycle evaluation and test specimens for material property characterization, and reliability prediction model prepared to predict stator performance in the simulated engine environment are considered. The status and description of the work performed for the reliability prediction modeling, stator fabrication, material property characterization, and ceramic stator evaluation efforts are reported.
Statistical information relating to the number of gas turbine engine rotor failures which occurred during 1979 in commercial aviation service use is provided. The predominant failure mode involved blade fragments, 84 percent of which were contained. No uncontained disk failures occurred and although fewer rotor rim and seal failures occurred, 100 percent and 50 percent, respectively, were uncontained. Sixty-eight percent of the 157 rotor failures occurred during the take-off and climb stages of flight.
A study was conducted to access the feasibility of reclaiming T55-L-712 turbine engine compressor housings with an 88 wt % aluminum -- 12 wt % silicon alloy applied by the plasma spray processes. Tensile strength testing was conducted on as-sprayed and thermally cycled test specimens which were plasma sprayed from 0.020 to 0.100 in. Satisfactory tensile strength valves were observed in the as-sprayed tensile specimens. There was essentially no decrease in tensile strength after thermally cycling the tensile specimens.