Engineering in 5 B61 Systems Engineering: Aircraft Compatibility
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Salazar, Ryan David↗
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Characterizing Flow Instabilities During Transient Events in the Turbine Rim Seal Cavity
Abstract Gas turbine engine design requires considerations not only for long-term steady operation but also for critical transient events. Aircraft engines undergo significant stress during takeoff and landing, while power generation turbines must be flexible for hot restarts as renewable energy sources come online and offline. During these transient cycles, engines sustain wear and degradation that can lead to a reduction in the lifespan of their components and more frequent, costly maintenance. Cooling flows are often used to mitigate these effects, but can lead to complex and problematic flow interactions. This study uses high-frequency response pressure probes and heat flux gauges in the rim seal cavity of a one-stage research turbine to characterize the properties of large-scale flow structures during transient operation. A continuous-duration turbine testing facility provides the ability to assess the importance of these transients by first reaching steady-state operation before imposing transient behaviors. Although previous studies have conducted similar measurements for steady purge flows and wheel speeds, varying these parameters to simulate transient effects revealed several unique phenomena not identifiable with discrete steady measurements. The measurement approach connects the varied transient parameter to the behavior of the flow structures to enable a better understanding of the type of instability observed and the root cause of its formation. In particular, a relationship between instability cell formation and rim sealing effectiveness was identified using experimental data and was supported through computational simulations.
Engineering↗
Development of Hydrogen Burner for FT4000® Aeroderivative Engine - Final Report
This report details an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas and ending with improved nozzle concepts for fully robust operation with 100% hydrogen. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) emissions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The design of new fuel/air mixer concepts to improve durability and operability with high hydrogen levels was also completed. A total of eleven new concepts were developed and analyzed, ranging from modifications to the bill-of-materials nozzle to fully clean sheet designs. The concepts were evaluated with non-reacting and reacting flow evaluations to assess the performance of the new hardware designs. Non-reacting tests included Phase Doppler Particle Analysis (PDPA) for droplet size and velocity, mechanical patternation for liquid water flux, and planar laser induced fluorescence (PLIF) with acetone-seeding for gaseous fuel/air mixing characterization. Five scaled candidate fuel nozzle designs, in addition to a scaled bill-of-materials nozzle, were then successfully evaluated in an atmospheric pressure burner rig. The nozzles were evaluated for performance with natural gas, hydrogen/natural gas blends, and pure hydrogen. For 100% hydrogen, the nozzles were evaluated with and without water injection. Optical and infrared imaging of the flame and fuel nozzle was captured. NOx emissions were sampled from fixed emissions probes. The results show measurable differences between the various designs, and the data was used to down-select the two most promising designs to advance to future full pressure rig testing. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water. Two promising nozzle designs have been developed to enable fully robust operation with up to 100% hydrogen. These nozzles require validation at full baseload operating conditions before they can be introduced to the field.
03 NATURAL GAS↗
OPERATION OF FT4000® SINGLE NOZZLE COMBUSTOR WITH HIGH HYDROGEN
This paper reports initial results from an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) missions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water.
power generation↗
Data-driven analysis of relight variability of jet fuels induced by turbulence
For safety purposes, reliable reignition of aircraft engines in the event of flame blow-out is a critical requirement. Typically, an external ignition source in the form of a spark is used to achieve a stable flame in the combustor. However, such forced turbulent ignition may not always successfully relight the combustor, mainly because the state of the combustor cannot be precisely determined. Uncertainty in the turbulent flow inside the combustor, inflow conditions, and spark discharge characteristics can lead to variability in sparking outcomes even for nominally identical operating conditions. Prior studies have shown that of all the uncertain parameters, turbulence is often dominant and can drastically alter ignition behavior. For instance, even when different fuels have similar ignition delay times, their ignition behavior in practical systems can be completely different. In practical operating conditions, it is challenging to understand why ignition fails and how much variation in outcomes can be expected. The focus of this work is to understand relight variability induced by turbulence for two different aircraft fuels, namely Jet-A and a variant named C1. A detailed, previously developed simulation approach is used to generate a large number of successful and failed ignition events. Using this data, the cause of misfire is evaluated based on a discriminant analysis that delineates the difference between turbulent initial conditions that lead to ignition or failure. From the discriminant analysis, a compressed sensing algorithm is then applied to help pinpoint the locations of relevant turbulent features. Findings from the discriminant analysis are confirmed with the time history of near kernel properties. Next, a clustering strategy is used to identify ignition and misfire modes. With this approach, it was determined that the cause of ignition failure is different for the two fuels. While it was found that Jet-A is influenced by fuel entrainment, C1 was found to be more sensitive to small scale turbulence features. Finally, a larger variability is found in the ignition modes of C1, which can be subject to extreme events induced by kernel breakdown.
42 ENGINEERING↗
Solving Recent Challenges for Wrought Ni-Base Superalloys
This paper reviews the status of technology in design and manufacture of new wrought 21 polycrystalline Ni-base superalloys for critical engineering applications. There is a strong 22 motivation to develop new alloys that are capable of operating at higher temperatures to 23 realise improvements in thermal efficiency, which are necessary to achieve environmental 24 targets for reduced emissions of harmful green-house gases. From the aerospace sector, 25 the development of new powder metallurgy and ingot metallurgy alloys are discussed for 26 disk rotor and static applications. New compositions for powder metallurgy contain about 27 50-55% of gamma prime (γ') strengthening precipitates to ensure components operate 28 successfully at temperatures up to 788°C (1450°F). In contrast, new compositions for ingot 29 metallurgy aim to occupy a design space in temperature capability between Alloy 718 and 30 current powder alloys that are in-service, and show levels of γ' of about 30-44%. The focus 31 in developing these alloys was design for manufacturability. To complement the aerospace 32 developments, a review of work to understand the suitability of candidate alloys for multiple 33 applications in Advanced-Ultra Supercritical (AUSC) power plants has been undertaken by 34 Detrois, Jablonski and Hawk from the National Energy Technology Laboratory. In these 35 power plants, steam temperatures are required to reach 700-760°C. The common thread is 36 to develop alloys that demonstrate a combination of high temperature properties, which are 37 reliant on both the alloy composition and microstructure and can be produced readily at the 38 right price. For the AUSC applications, the emphasis is on high temperature strength, long 39 term creep life, phase stability, oxidation resistance and robust welding for fabrications. 40 Whereas for powder disk rotors in aircraft engines, the priority is enhanced resistance to 41 time dependent crack growth, phase stability and resistance to environmental damage, while 42 extending the current strength levels, which are shown by existing alloys, to higher 43 temperatures.
36 MATERIALS SCIENCE↗
Realizing "Net-Zero-Carbon" Sustainable Aviation Fuel
The aviation industry needs renewable and fungible jet fuel - commonly referred to as sustainable aviation fuel (SAF) - to minimize emissions and increase efficiencies. SAF can displace the same, if not more, CO2 equivalent emissions (CO2eq), reduce contrail formation, and increase engine-aircraft efficiencies. Flight represents ~10% of transportation greenhouse gas emissions, with the global consumption of ~400 billion liters of fossil jet fuel in 2019 releasing over 900 million tons of CO2eq. Even with impacts from the COVID-19 global pandemic, the aviation sector is projected to grow with passenger miles expected to double by 2050, relative to 2010. As such, there is an urgent need to produce drop-in aviation fuel from renewables with a dramatically lower carbon footprint.
biojet↗
Characterization of precipitation in gradient Inconel 718 superalloy
Inconel 718 (IN718) superalloy is a well-established material for the application of aircraft engine and power generator due to its excellent performance at high temperatures. The outstanding mechanical properties of IN718 are largely determined by the precipitates. Here, we investigated the precipitation behaviors and the corresponding mechanical properties of the heat-treated gradient IN718 alloy. The microscopy studies reveal that high-density hexagonal η phase with chemistry of Ni 3 (Al,Ti,Nb) formed in the nanograined IN718 alloy after annealing at 700 °C. Additionally, the compressive stress introduced during severe plastic deformation may have prohibited the formation of γ” phase while accelerated the precipitation of γ’ phase, consequently favoring the precipitation of η phase. The corresponding evolution of mechanical behavior of gradient IN718 alloy is investigated.
36 MATERIALS SCIENCE↗
Understanding the role of flow dynamics in thermoacoustic combustion instability
Thermoacoustic combustion instability is one of the most challenging operational issues in several high-performance, low-emissions combustion technologies, including gas turbines, aircraft engines, rockets, and industrial boilers. Driven by the coupling between combustor acoustics and flame heat release rate fluctuations, thermoacoustic combustion instability can lead to reduced operability, increased emissions, and, in the most extreme cases, catastrophic failure of combustor components. The feedback loop between acoustics and combustion is often facilitated by fluid mechanic oscillations, referred to as “velocity coupling,” whereby acoustic oscillations drive flow fluctuations, which in turn create fluctuations in the flame. The character of these fluid mechanic oscillations is highly dependent on the structure of the flow field and the receptivity of the flow to external excitation. Combustor flow fields use features like fluid recirculation and shear to enhance flame holding and reduce emissions, but these are also the same features that can make the flow receptive to acoustic excitation or even drive self-excited oscillations. Here, in this paper, we discuss the basics of thermoacoustic instability with a focus on the role of hydrodynamic oscillations in typical combustor flows. To facilitate this discussion, we explore the hydrodynamic instability characteristics of several key combustor unit flows (wakes, swirling jets, etc.) and show how the hydrodynamic stability of a flow is an important consideration in determining a combustor’s propensity for thermoacoustic oscillations. Several examples of coupling between hydrodynamics and thermoacoustics are discussed to illustrate this important link. The paper concludes by discussing the potential for designing flow fields that are thermoacoustic instability resistant, either through a reduction in the receptivity of the flow or through nonlinear coupling mechanisms by which self-excited flow instabilities can suppress velocity-coupled combustion oscillations.
42 ENGINEERING↗
Nucleation and Contrail Formation
Condensation trails, or contrails, are aircraft-induced cirrus clouds. They come from the formation of water droplets, later converting to ice crystals as a result of water vapor condensing on aerosols either emitted by the aircraft engines or already present in the upper atmosphere. While there is ongoing debate about their true impact, contrails are estimated to be a major contributor to climate forcing from aviation. We remind that air transportation currently accounts for about 5 % of the global anthropogenic climate forcing, and that it is anticipated that air traffic will double in the coming decade or two. The expected growth reinforces the urgency of the need to develop a plan to better understand contrail formation and persistence, and deploy means to reduce or avoid contrail formation, or greatly mitigate their impact. It is evident that contrails should be part of the picture when developing a plan to make the aviation sector sustainable.
54 ENVIRONMENTAL SCIENCES↗
High temperature thick film sensor development based on doped lanthanum chromites refractory semiconductors materials
High temperature advanced sensing materials have generated high demand due the high accuracy temperature measurements requirements for process optimization, controlling and sensing. Some technological applications of harsh conditions sensing include monitoring tiles of space shuttles, rotating bearings in aircraft engines, turbines, jet engines dynamics and chemical reactors. High temperature conditions limit the sensing strategies, where typically traditional metal thermocouples are unstable, and the sensing options are limited to optical spectroscopy methods. Recently, refractory semiconductors thick- and thin-film thermocouples have been developed and, in many cases, preferred over conventional metallic thermocouples due their spatial resolution, and capability of direct deposition on any surface. Rare earth chromites ceramics materials, exhibit some properties of interest for high temperature sensing technologies development, such as: high microstructure and sintering stability, excellent conductive behavior at high temperatures, and matching thermal expansion coefficients relative to other conductors and refractory ceramics. In this work, high performance ultra-high temperature thermocouples using p-type and n-type doped lanthanum chromites materials were fabricated and tested at temperatures up to 1500 o C. Thermoelectric voltage, Seebeck Coefficients were established for all devices, evidencing high stability and performance in prolongated operational time and harsh conditions.
20 FOSSIL-FUELED POWER PLANTS↗
Aviation Fuel Characterization at Operationally Relevant Conditions
To accelerate approval and potentially expand the allowable property range for aviation fuels, we are using high performance computing simulations to reveal fuel property effects on aviation combustor performance. These simulations are supported by fuel property measurements over temperatures and pressures that the fuel experiences in an aircraft engine and by validated chemical kinetics models for SAF combustion. Here we report density, viscosity, and surface tension results for conventional jet fuel and multiple synthetic fuels from -30 degrees Celsius to 200 degrees Celsius (-40 degrees Celsius for viscosity) and 1 atm to 70 atm including an assessment of method repeatability. Properties of surrogate mixtures are also investigated. Distillation, ICN, LHV, flashpoint, and Cp are also reported, and data are being used to develop models to predict fuel properties from composition (GCxGC).
33 ADVANCED PROPULSION SYSTEMS↗
Real-time Data Analytics for Condition Monitoring of Complex Industrial Systems
Modern industrial systems are now fitted with several sensors for condition monitoring. This is advantageous because these sensors can provide mass amounts of data that have the potential for aiding in tasks such as fault detection, diagnosis, and prognostics. However, the information valuable for performing these tasks is often clouded in noise and must be mined from high-dimensional data structures. Therefore, this dissertation presents a data analytics framework for performing these condition monitoring tasks using high-dimensional data. Demonstrations of this framework are detailed for challenges related to power generation systems in automobiles, power plants, and aircraft engines. These implementations leverage data collected from state-of-the-art, industry class test-rigs. Results indicate the ability of this framework to develop effective methodologies for condition monitoring of complex systems.
Peters, Benjamin↗
Power Electronics and Electric Machines for Advanced Aircraft
Power electronics and electric machines are critical components of efficient, high-performance aircraft - from fixed-wing turbine to electric vertical takeoff and landing aircraft and beyond. Improvements to these components create enormous energy efficiencies, enable cost savings, and ensure fail-safe operations. National Renewable Energy Laboratory researchers are developing innovative power electronics, electric motors, integrated electric traction drives, and thermal management systems to build highly efficient, lightweight, ultrareliable powertrains for aircraft.
42 ENGINEERING↗
Mechanism, Thermochemistry, and Kinetics for the CH + N 2 Reaction Leading to Prompt NO Formation in Combustion
Here, the reaction of CH + N 2 forming H + NCN is a remarkable example of activation of the nitrogen triple bond and is an important source of prompt NO in combustion. The reaction pathway is complex and proceeds through two competing mechanisms: a cyclic addition channel initiated by c-HC(NN) and a chain-addition channel initiated by HCNN, both of which eventually form HNCN prior to dissociation to H + NCN. This work reinvestigates this reaction with composite coupled cluster protocols, including a novel spin-flip equation of motion coupled cluster scheme, combined with pragmatic two-dimensional master equation simulations of the resulting rate coefficients. These improved calculations predict the CH + N 2 rate coefficient between the two more recent previous theoretical results and reduce the uncertainties of the best theoretical models of this reaction to less than a factor of 1.3. Additionally, we provide a closer theoretical investigation of the simultaneous dependence of the CH + N 2 rate coefficient on pressure and temperature, and affirm that collisionally stabilized HNCN, another potential source of prompt NO, emerges as an appreciable product of this reaction under conditions relevant to automotive internal combustion engines and aircraft gas turbine engines.
Nguyen, Thanh Lam [Univ. of Florida, Gainesville, ↗
2024 Sustainable Aviation Energy Conference: 5 Key Messages From the Sustainable Aviation Fuel Workshop
At the 2024 Sustainable Aviation Energy Conference, more than 100 aviation leaders gathered in Dallas, Texas, to discuss collaboration and research needed to clear the path to widespread adoption of sustainable aviation technologies. During open workshops, participants from state and federal agencies; airports; aircraft and engine manufacturers; liquid fuel producers; and other stakeholder groups brainstormed the biggest barriers and opportunities for realizing a sustainable aviation ecosystem. This fact sheets presents five key messages and discussion points that emerged during a workshop on sustainable aviation fuel.
advanced air mobility↗
2024 Sustainable Aviation Energy Conference: 5 Key Messages From the Airport Enabling Efforts Workshop
At the 2024 Sustainable Aviation Energy Conference, more than 100 aviation leaders gathered in Dallas, Texas, to discuss collaboration and research needed to clear the path to widespread adoption of sustainable aviation technologies. During open workshops, participants from state and federal agencies; airports; aircraft and engine manufacturers; liquid fuel producers; and other stakeholder groups brainstormed the biggest barriers and opportunities for realizing a sustainable aviation ecosystem. This fact sheets presents five key messages and discussion points that emerged during a workshop on airport enabling efforts.
advanced air mobility↗