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A trade study was performed on twenty-one digital output interface schemes for gas turbine electronic controls to select the most promising scheme based on criteria of reliability, performance, cost, and sampling requirements. The most promising scheme, a digital effector with optical feedback of the fuel metering valve position, was designed.
The paper surveys programs for improving the environmental resistance of gas turbine and power system materials to oxidation and hot corrosion. A computer program Corest has been produced which provides an initial method for predicting long-time metal loss using short-time oxidation data. The role of the coefficient of thermal expansion mismatch on oxide spallation is being studied. A paralinear oxidation attack model in conjunction with regression analysis of weight change data has been applied to the study of oxidation and hot corrosion attack of some Ni-Cr-Al system alloys. Oxide-dispersion strengthened alloys based on the Ni-Cr-Al system are being developed. Sodium sulfate formation during turbine combustion is being investigated from a thermodynamic viewpoint.
A computerized method was developed to estimate weight and envelope dimensions of large and small gas turbine engines within + or - 5% to 10%. The method is based on correlations of component weight and design features of 29 data base engines. Rotating components were estimated by a preliminary design procedure which is sensitive to blade geometry, operating conditions, material properties, shaft speed, hub tip ratio, etc. The development and justification of the method selected, and the various methods of analysis are discussed.
The low-cycle, creep-fatigue characteristics of the advanced gas turbine disk alloy, AF2-1DA have been determined at 1400 F and are presented in terms of the method of strainrange partitioning (SRP). The mean stresses which develop in the PC and CP type SRP cycles at the lowest inelastic strainrange were observed to influence the cyclic lives to a greater extent than the creep effects and hence interfered with a conventional interpretation of the results by SRP. A procedure is proposed for dealing with the mean stress effects on life which is compatible with SRP.
The low-cycle, creep-fatigue characteristics of the advanced gas turbine disk alloy, AF2-1DA have been determined at 1400 F and are presented in terms of the method of strainrange partitioning (SRP). The mean stresses which develop in the PC (tensile Plasticity reversed by compressive Creep) and CP (tensile Creep reversed by compressive Plasticity) type SRP cycles at the lowest inelastic strainrange were observed to influence the cyclic lives to a greater extent than the creep effects and hence interfered with a conventional interpretation of the results by SRP. A procedure is proposed for dealing with the mean stress effects on life which is compatible with SRP.
A method is presented that performs a rapid, reasonably accurate preliminary pitchline optimization of axial gas turbine annular flowpath geometry, as well as an initial estimate of blade profile shapes, given only a minimum of thermodynamic cycle requirements. No geometric parameters need be specified. The following preliminary design data are determined: (1) the optimum flowpath geometry, within mechanical stress limits; (2) initial estimates of cascade blade shapes; (3) predictions of expected turbine performance. The method uses an inverse calculation technique whereby blade profiles are generated by designing channels to yield a specified velocity distribution on the two walls. Velocity distributions are then used to calculate the cascade loss parameters. Calculated blade shapes are used primarily to determine whether the assumed velocity loadings are physically realistic. Model verification is accomplished by comparison of predicted turbine geometry and performance with four existing single stage turbines.
The use of compressed air was suggested to increase the reliability and motor lifetime of a gas turbine engine. Experiments were carried out and the results are shown in the form of the variation in circumferential force as a function of the entry angle of the working jet onto the turbine blade. The described start-up method is recommended for use with massive rotors.
The ceramic component design, manufacturing and inspection technologies under development for the AGT 100 automotive gas turbine promise to meet marketplace cost and performance criteria. Especially consequential developments are noted toward this goal in the case of net and near-net shape component fabrication. Integral turbine rotors, scrolls, combustors, support structures and heat exchangers have been successfully produced and evaluated. Consistency of material properties have yet to be achieved for the processing methods in question, however.
An experimental program was conducted to track the variation in soot loading in a generic gas turbine combustor. The burner is a 12.7-cm dia cylindrical device consisting of six sheet-metal louvers. Determination of soot loading along the burner length is achieved by measurement at the exit of the combustor and then at upstream stations by sequential removal of liner louvers to shorten burner length. Alteration of the flow field approaching and within the shortened burners is minimized by bypassing flow in order to maintain a constant linear pressure drop. The burner exhaust flow is sampled at the burner centerline to determine soot mass concentration and smoke number. Characteristic particle size and number density, transmissivity of the exhaust flow, and local radiation from luminous soot particles in the exhaust are determined by optical techniques. Four test fuels are burned at three fuel-air ratios to determine fuel chemical property and flow temperature influences. Particulate concentration data indicate a strong oxidation mechanism in the combustor secondary zone, though the oxidation is significantly affected by flow temperature. Soot production is directly related to fuel smoke point.
Progress toward developing life models for simulating the behavior of thermal barrier coatings in aircraffft gas turbine engines is discussed. A preliminary laboratory model is described as are current efforts to develop engine-capable models. Current understanding of failure mechanisms is also summarized.
Researchers at the NASA Glenn Research Center, in collaboration with industry, are reducing gas turbine engine emissions by studying visually the air-fuel interactions and combustion processes in combustors. This is especially critical for next generation engines that, in order to be more fuel-efficient, operate at higher temperatures and pressures than the current fleet engines. Optically based experiments were conducted in support of the Ultra-Efficient Engine Technology program in Glenn's unique, world-class, advanced subsonic combustion rig (ASCR) facility. The ASCR can supply air and jet fuel at the flow rates, temperatures, and pressures that simulate the conditions expected in the combustors of high-performance, civilian aircraft engines. In addition, this facility is large enough to support true sectors ("pie" slices of a full annular combustor). Sectors enable one to test true shapes rather than rectangular approximations of the actual hardware. Therefore, there is no compromise to actual engine geometry. A schematic drawing of the sector test stand is shown. The test hardware is mounted just upstream of the instrumentation section. The test stand can accommodate hardware up to 0.76-m diameter by 1.2-m long; thus sectors or small full annular combustors can be examined in this facility. Planar (two-dimensional) imaging using laser-induced fluorescence and Mie scattering, chemiluminescence, and video imagery were obtained for a variety of engine cycle conditions. The hardware tested was a double annular sector (two adjacent fuel injectors aligned radially) representing approximately 15 of a full annular combustor. An example of the two-dimensional data obtained for this configuration is also shown. The fluorescence data show the location of fuel and hydroxyl radical (OH) along the centerline of the fuel injectors. The chemiluminescence data show C2 within the total observable volume. The top row of this figure shows images obtained at an engine low-power condition, and the bottom row shows data from a higher power operating point. The data show distinctly the differences in flame structure between low-power and high-power engine conditions, in both location and amount of species produced (OH, C2) or consumed (fuel). The unique capability of the facility coupled with its optical accessibility helps to eliminate the need for high-pressure performance extrapolations. Tests such as described here have been used successfully to assess the performance of fuel-injection concepts and to modify those designs, if needed.
One of the key technology challenges for the use of hydrogen in gas turbine engines is the performance of the combustion system, in particular the fuel injectors. To investigate the combustion performance of gaseous hydrogen fuel injectors flame tube combustor experiments were performed. Tests were conducted to measure the nitrogen oxide (NO(x)) emissions and combustion performance at inlet conditions of 588 to 811 K, 0.4 to 1.4 MPa, and equivalence ratios up to 0.48. All the injectors were based on Lean Direct Injection (LDI) technology with multiple injection points and quick mixing. One challenge to hydrogen-based premixing combustion systems is flashback since hydrogen has a reaction rate over 7 times that of Jet-A. To reduce the risk, design mixing times were kept short and velocities high to minimize flashback. Five fuel injector designs were tested in 6.35- and 8.9-cm-diameter flame tubes with non-vitiated heated air and gaseous hydrogen. Data is presented on measurements of NO(x) emissions and combustion efficiency for the hydrogen injectors at 2.540, 7.937, and 13.652 cm from the injector face. Results show that for some configurations, NO(x) emissions are comparable to that of state of the art Jet-A LDI combustor concepts.
One of the key technology challenges for the use of hydrogen in gas turbine engines is the performance of the combustion system, in particular the fuel injectors. To investigate the combustion performance of gaseous hydrogen fuel injectors flame tube combustor experiments were performed. Tests were conducted to measure the nitrogen oxide (NOx) emissions and combustion performance at inlet conditions of 600 to 1000 deg F, 60 to 200 pounds per square inch absolute (psia), and equivalence ratios up to 0.48. All the injectors were based on Lean Direct Injection (LDI) technology with multiple injection points and quick mixing. One challenge to hydrogen based premixing combustion systems is flashback since hydrogen has a reaction rate over seven times that of Jet-A. To reduce the risk, design mixing times were kept short and velocities high to minimize flashback. Five fuel injector designs were tested in 2.5 and 3.5-in. diameter flame tubes with non-vitiated heated air and gaseous hydrogen. Data is presented on measurements of NOx emissions and combustion efficiency for the hydrogen injectors at 1.0, 3.125, and 5.375 in. from the injector face. Results show that for some configurations, NOx emissions are comparable to that of state of the art Jet-A LDI combustor concepts.
Method for controlling the clearance between rotating and stationary components of a gas turbine engine are disclosed. Techniques for achieving close correspondence between the radial position of rotor blade tips and the circumscribing outer air seals are disclosed. In one embodiment turbine case temperature modifying air is provided in flow rate, pressure and temperature varied as a function of engine operating condition. The modifying air is scheduled from a modulating and mixing valve supplied with dual source compressor air. One source supplies relatively low pressure, low temperature air and the other source supplies relatively high pressure, high temperature air. After the air has been used for the active clearance control (cooling the high pressure turbine case) it is then used for cooling the structure that supports the outer air seal and other high pressure turbine component parts.
This paper summarizes research on the lean direct injection (LDI) combustor concept for aero-gas turbine combustors. The focus of this paper is one particular family of lean direct injection designs, swirl-venturi lean direct injection (SV-LDI). SV-LDI is characterized by the airpath: an air swirler followed by a converging-diverging venturi. For most SV-LDI configurations, a fuel injector is inserted through the center of the air swirler, with the fuel injector tip at or near the venturi throat. Several design variables were studied. These included fuel injector tip location, air swirler blade thickness, air swirler blade angle, and fuel-air mixer size. Moving the fuel injector tip slightly upstream or downstream of the venturi throat has at most a small impact on NOx emissions. Changing the blade thickness also does not affect NOx emissions. Changing the swirler blade angle has a significant effect on NOx emissions. Decreasing swirler blade angle, and thus decreasing swirl number, decreases the NOx emissions at lower flame temperatures (below about 1800 K). However, the slope of the NOx vs. flame temperature curve is higher for lower swirl numbers. Finally, decreasing the fuel-air mixer size initially decreases NOx emissions. However, there may be an optimum fuel-air mixer size below which NOx emissions do not continue to decrease.
Use of air-assist fuel nozzle to reduce exhaust emissions from gas turbine combustor at simulated idle conditions - J-57 engine
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.
Thermal barrier coating design option offers benefit in terms of reduced electricity costs when used in utility gas turbines. Options considered include: increased firing temperature, increased component life, reduced cooling air requirements, and increased corrosion resistance (resulting in increased tolerance for dirty fuels). Performance and cost data were obtained. Simple, recuperated and combined cycle applications were considered, and distillate and residual fuels were assumed. The results indicate that thermal barrier coatings could produce large electricity cost savings if these coatings permit turbine operation with residual fuels at distillate-rated firing temperatures. The results also show that increased turbine inlet temperature can result in substantial savings in fuel and capital costs.