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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records

Present capabilities and future requirements for computer-aided geometric modeling in the design and manufacture of gas turbine

Gas turbine engine design requires the ability to rapidly develop complex structures which are subject to severe thermal and mechanical operating loads. As in all facets of the aerospace industry, engine designs are constantly driving towards increased performance, higher temperatures, higher speeds, and lower weight. The ability to address such requirements in a relatively short time frame has resulted in a major thrust towards integrated design/analysis/manufacturing systems. These computer driven graphics systems represent a unique challenge, with major payback opportunities if properly conceived, implemented, and applied.

Caille, E.↗

Computational Design to Advance AM Fabrication of High Gamma Prime Alloys for Hot Gas Path Components in Gas Turbine Engines: A Pathway to Enhanced Gas Turbine Efficiency and Energy Saving (Final CRADA Report)

Raising turbine inlet temperature is a key lever for improving industrial gas-turbine efficiency and power output, but it increases thermo-mechanical demands on hot-gas-path components. Additive manufacturing (AM), particularly laser powder bed fusion (L-PBF), enables complex internal cooling features in critical components such as turbine tip shoes that are difficult to produce by conventional casting. However, qualification of new high-temperature AM alloys and aggressive geometries is often limited by trial-and-error iteration of build parameters and post-build heat treatments, with cracking during stress relieving or hot isostatic pressing (HIP) being a recurring failure mode.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

An overview of aerospace gas turbine technology of relevance to the development of the automotive gas turbine engine

Technology areas related to gas turbine propulsion systems with potential for application to the automotive gas turbine engine are discussed. Areas included are: system steady-state and transient performance prediction techniques, compressor and turbine design and performance prediction programs and effects of geometry, combustor technology and advanced concepts, and ceramic coatings and materials technology.

Evans, D. G.↗

Thermo-economic analysis of a solid oxide fuel cell-gas turbine hybrid with commercial off-the-shelf gas turbine

The thermodynamic and economic performance of a natural gas-fueled solid oxide fuel cell (SOFC)-gas turbine (GT) hybrid system with a commercial off-the-shelf GT is investigated. Until today, commercial GTs are primarily engineered for the direct use of energy dense fuels, such as natural gas, and the integration of commercial GTs into a SOFC-GT hybrid remains challenging. In this work technically feasible and economically viable GT operating modes are identified to gauge the technology’s competitiveness on the free market. Steady state, full load operating conditions were established for various GT operating modes: I) constant spool speed operation, II) variable spool speed operation and III) partially closed compressor inlet guide vanes. For each GT operating mode, the performance was investigated over a range of SOFC fuel utilization factors, while considering physical constraints inside the SOFC, such as local temperature gradients in flow direction as well as overall cell temperature differences. The results of the thermodynamic evaluation served as inputs for the economic analysis of the SOFC-GT hybrid power plant. The results show that the integration of an off-the-shelf GT not only results in a significant derating of the GT, but also substantially impacts the SOFC operation, the main power producer in this SOFC-GT hybrid. To maximize the SOFC power output it is desirable operate the GT in a region of high air mass flow rates and low pressure ratios, which increases the number of stacks that can be accommodated and reduces the SOFC cooling requirement. The lowest costs of electricity are obtained at constant spool speed operation, while the highest efficiencies are reached at variable spool speed operation. Critical for the integration of off-the-shelf GTs, which historically have been designed for natural gas, is the surge margin. The largest surge margins are obtained by closing the compressor inlet guide vanes. Furthermore, higher SOFC fuel utilization factors are shown to increase the surge margin as the turbine firing temperature is decreased.

25 ENERGY STORAGE↗

Integrated Turbine Tip Clearance and Gas Turbine Engine Simulation

Gas turbine compressor and turbine blade tip clearance (i.e., the radial distance between the blade tip of an axial compressor or turbine and the containment structure) is a major contributing factor to gas path sealing, and can significantly affect engine efficiency and operational temperature. This paper details the creation of a generic but realistic high pressure turbine tip clearance model that may be used to facilitate active tip clearance control system research. This model uses a first principles approach to approximate thermal and mechanical deformations of the turbine system, taking into account the rotor, shroud, and blade tip components. Validation of the tip clearance model shows that the results are realistic and reflect values found in literature. In addition, this model has been integrated with a gas turbine engine simulation, creating a platform to explore engine performance as tip clearance is adjusted. Results from the integrated model explore the effects of tip clearance on engine operation and highlight advantages of tip clearance management.

gas path dynamics↗

Integrated Turbine Tip Clearance and Gas Turbine Engine Simulation

Gas turbine compressor and turbine blade tip clearance (i.e., the radial distance between the blade tip of an axial compressor or turbine and the containment structure) is a major contributing factor to gas path sealing, and can significantly affect engine efficiency and operational temperature. This paper details the creation of a generic but realistic high pressure turbine tip clearance model that may be used to facilitate active tip clearance control system research. This model uses a first principles approach to approximate thermal and mechanical deformations of the turbine system, taking into account the rotor, shroud, and blade tip components. Validation of the tip clearance model shows that the results are realistic and reflect values found in literature. In addition, this model has been integrated with a gas turbine engine simulation, creating a platform to explore engine performance as tip clearance is adjusted. Results from the integrated model explore the effects of tip clearance on engine operation and highlight advantages of tip clearance management.

aerothermodynamics↗

An Experimental Investigation of Fuel Staging In A Model Gas Turbine Combustor

Modern gas turbine engines are typically operated in a lean-premixed configuration in order to meet emissions requirements. Lean operation makes gas turbines more susceptible to combustion instability, which can cause catastrophic hardware failure if left unchecked. The spatially uneven distribution of fuel in a gas turbine combustor, known as fuel staging, is an effective way of suppressing instabilities. This dissertation examines the effect of both steady-state and transient fuel-staging in a model gas turbine combustor. First, the steady-state effect of fuel staging on nominally unstable operating conditions is examined. At 200 degrees Celsius and a bulk flow velocity of 26 m/s, the combustor undergoes self-excited instabilities when the equivalence ratio is between φ = 0.70 and φ = 0.74 when all nozzles are fueled equally. These instabilities are suppressed when the center nozzle equivalence ratio is increased to φ Staging = 0.85 and the outer nozzle equivalence ratio maintained at φ = 0.70 or when the global equivalence ratio is maintained at φ = 0.70 by increasing the center nozzle equivalence ratio to φ Staging = 0.74 and decreasing the outer nozzle equivalence ratio to φ Staging = 0.69. The staged p' RMS amplitudes are found to decrease with increasing equivalence ratio and the damping rates found to increase with increasing equivalence ratio. Next, axisymmetric fuel staging transients are conducted valve opening/closing timescales of 1, 16, 58, 4,000, and 10,000 ms, and equivalence ratios of φ staging = 0.75, 0.80, 0.85. It should be noted that these valve opening/closing timescales, referred to as τ Transient , differ from the actual fuel convection timescale that are summarized in Table 5.2. It is found that the combustor pressure fluctuation at the end of the transient strongly depends on staging equivalence ratio but not on τ Transient . Increasing the staging equivalence ratio decreased the staged- stable combustor pressure amplitude, similarly to the steady-state results. The staged-stable damping rate trends are insensitive to to τ Transient and increased with increasing staging equivalence ratio. The timescale of the transition, τ, is found to be sensitive to both τ Transient and the staging equivalence ratio. For a Modern gas turbine engines are typically operated in a lean-premixed configuration in order to meet emissions requirements. Lean operation makes gas turbines more susceptible to combustion instability, which can cause catastrophic hardware failure if left unchecked. The spatially uneven distribution of fuel in a gas turbine combustor, known as fuel staging, is an effective way of suppressing instabilities. This dissertation examines the effect of both steady-state and transient fuel-staging in a model gas turbine combustor. First, the steady-state effect of fuel staging on nominally unstable operating conditions is examined. At 200 degrees Celsius and a bulk flow velocity of 26 m/s, the combustor undergoes self-excited instabilities when the equivalence ratio is between φ = 0.70 and φ = 0.74 when all nozzles are fueled equally. These instabilities are suppressed when the center nozzle equivalence ratio is increased to φ Staging = 0.85 and the outer nozzle equivalence ratio maintained at φ = 0.70 or when the global equivalence ratio is maintained at φ = 0.70 by increasing the center nozzle equivalence ratio to φ Staging = 0.74 and decreasing the outer nozzle equivalence ratio to φ Staging = 0.69. The staged p' RMS amplitudes are found to decrease with increasing equivalence ratio and the damping rates found to increase with increasing equivalence ratio. Next, axisymmetric fuel staging transients are conducted valve opening/closing timescales of 1, 16, 58, 4,000, and 10,000 ms, and equivalence ratios of φ staging = 0.75, 0.80, 0.85. It should be noted that these valve opening/closing timescales, referred to as τ Transient , differ from the actual fuel convection timescale that are summarized in Table 5.2. It is found that the combustor pressure fluctuation at the end of the transient strongly depends on staging equivalence ratio but not on τ Transient . Increasing the staging equivalence ratio decreased the staged-stable combustor pressure amplitude, similarly to the steady-state results. The staged-stable damping rate trends are insensitive to to τ Transient and increased with increasing staging equivalence ratio. The timescale of the transition, τ, is found to be sensitive to both τ Transient and the staging equivalence ratio. For a Modern gas turbine engines are typically operated in a lean-premixed configuration in order to meet emissions requirements. Lean operation makes gas turbines more susceptible to combustion instability, which can cause catastrophic hardware failure if left unchecked. The spatially uneven distribution of fuel in a gas turbine combustor, known as fuel staging, is an effective way of suppressing instabilities. This dissertation examines the effect of both steady-state and transient fuel-staging in a model gas turbine combustor. First, the steady-state effect of fuel staging on nominally unstable operating conditions is examined. At 200 degrees Celsius and a bulk flow velocity of 26 m/s, the combustor undergoes self-excited instabilities when the equivalence ratio is between φ = 0.70 and φ = 0.74 when all nozzles are fueled equally. These instabilities are suppressed when the center nozzle equivalence ratio is increased to φ Staging = 0.85 and the outer nozzle equivalence ratio maintained at φ = 0.70 or when the global equivalence ratio is maintained at φ = 0.70 by increasing the center nozzle equivalence ratio to φ Staging = 0.74 and decreasing the outer nozzle equivalence ratio to φ Staging = 0.69. The staged p' RMS amplitudes are found to decrease with increasing equivalence ratio and the damping rates found to increase with increasing equivalence ratio. Next, axisymmetric fuel staging transients are conducted valve opening/closing timescales of 1, 16, 58, 4,000, and 10,000 ms, and equivalence ratios of φ staging = 0.75, 0.80, 0.85. It should be noted that these valve opening/closing timescales, referred to as τ Transient , differ from the actual fuel convection timescale that are summarized in Table 5.2. It is found that the combustor pressure fluctuation at the end of the transient strongly depends on staging equivalence ratio but not on τ Transient . Increasing the staging equivalence ratio decreased the staged- stable combustor pressure amplitude, similarly to the steady-state results. The staged-stable damping rate trends are insensitive to to τT Transient and increased with increasing staging equivalence ratio. The timescale of the transition, τ, is found to be sensitive to both τ Transient and the staging equivalence ratio. For a given τ Transient , the decay timescale decreased with increasing staging equivalence ratio. For 1, 16, and 58 ms transients, τ does not depend on τ Transient , though it does strongly depend on direction, where instability onset cases have longer and more variable τ than instability decay cases. The same dependence of τ on direction is seen for the 4,000 and 10,000 ms transients. However, unlike the short duration transients, τ does depend on τ Transient as would be expected. Phase space reconstruction shows the instability is a harmonic limit cycle with a single frequency. The instantaneous phase images shows the center region of the combustor goes out-of-phase first followed by the rest of the combustor. Finally, asymmetric fuel staging tests are conducted. It is found that non-axisymmetric staging can be as effective as axisymmetric staging, although small hardware variations between nozzles can affect the the minimum staging equivalence ratio that consistently suppresses the instability. These changes in the bifurcation equivalence ratio can make staging configurations appear less effective; however, both axisymmetric and non-axisymmetric staging configurations exhibit similar staged-stable p' RMS , damping rates, and instability transition times for equivalence ratios greater than the bifurcation equivalence ratio. Instantaneous phase images show similar instantaneous phase relationship structures in the staged nozzle (center or outer), suggesting that the instability suppression mechanism is similar in each case. This result is surprising given that the time-averaged flame shapes are very different between axisymmetric and non-axisymmetric staging configurations. The similar effectiveness of axisymmetric and non-axisymmetric staging in this geometry is attributed to the fact that the instability mode is a nominally axisymmetric plane wave. It is hypothesized that non-axisymmetric staging configurations will likely be more effective than axisymmetric staging configurations when the instability mode shape is asymmetric (such as a circumferential wave).

Culler, Wyatt↗

Impact of Detailed Parameter Modeling of Open-Cycle Gas Turbines on Production Cost Simulation: Preprint

Flexible resources are increasingly important as variable renewable energy deployment in the power system increases. Although many systems are transitioning away from fossil fuels, open-cycle gas turbines are likely to play an important balancing role for some time, thus requiring accurate modeling of their operational parameters. This paper explores the impact of detailed representation of three operational parameters - start- up costs, run-up rates, and forced outage rates - in the production cost model of a system as it adopts higher levels of wind and solar. Using PLEXOS simulations of the NREL-118 bus test system, the study examines how more detailed parameter modeling affects outcomes such as the number of start-ups and shutdowns, ramping and total generation costs for open-cycle gas turbines, as renewable energy levels increase. The results suggest the value of detailed parameter modeling and continued research on combustion turbines' ability to provide flexibility.

economic dispatch↗

An overview of aerospace gas turbine technology of relevance to the development of the automotive gas turbine engine

The NASA-Lewis Research Center (LeRC) has conducted, and has sponsored with industry and universities, extensive research into many of the technology areas related to gas turbine propulsion systems. This aerospace-related technology has been developed at both the component and systems level, and may have significant potential for application to the automotive gas turbine engine. This paper summarizes this technology and lists the associated references. The technology areas are system steady-state and transient performance prediction techniques, compressor and turbine design and performance prediction programs and effects of geometry, combustor technology and advanced concepts, and ceramic coatings and materials technology.

Evans, D. G.↗

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗

Cooling of Gas Turbines: Analysis of Rotor and Blade Temperatures in Liquid-Cooled Gas Turbines - 3

A theoretical analysis of the radial temperature distribution through the rotor and constant cross sectional area blades near the coolant passages of liquid cooled gas turbines was made. The analysis was applied to obtain the rotor and blade temperatures of a specific turbine using a gas flow of 55 pounds per second, a coolant flow of 6.42 pounds per second, and an average coolant temperature of 200 degrees F. The effect of using kerosene, water, and ethylene glycol was determined. The effect of varying blade length and coolant passage lengths with water as the coolant was also determined. The effective gas temperature was varied from 2000 degrees to 5000 degrees F in each investigation.

Brown, W. Byron↗

Heat Transfer in Gas Turbines

The turbine gas path is a very complex flow field. This is due to a variety of flow and heat transfer phenomena encountered in turbine passages. This manuscript provides an overview of the current work in this field at the NASA Glenn Research Center. Also, based on the author's preference, more emphasis is on the computational work. There is much more experimental work in progress at GRC than that reported here. While much has been achieved, more needs to be done in terms of validating the predictions against experimental data. More experimental data, especially on film cooled and rough turbine blades, are required for code validation. Also, the combined film cooling and internal cooling flow computation for a real blade is yet to be performed. While most computational work to date has assumed steady state conditions, the flow is clearly unsteady due to the presence of wakes. All this points to a long road ahead. However, we are well on course.

Garg, Vijay K.↗

Development of sprayed ceramic seal systems for turbine gas path sealing

A ceramic seal system is reported that employs plasma-sprayed graded metal/ceramic yttria stabilized zirconium oxide (YSZ). The performance characteristics of several YSZ configurations were determined through rig testing for thermal shock resistance, abradability, and erosion resistance. Results indicate that this type of sealing system offers the potential to meet operating requirements of future gas turbine engines.

Bill, R. C.↗