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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limtis. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS2012

Durability Challenges for Next Generation of Gas Turbine Engine Materials

Aggressive fuel burn and carbon dioxide emission reduction goals for future gas turbine engines will require higher overall pressure ratio, and a significant increase in turbine inlet temperature. These goals can be achieved by increasing temperature capability of turbine engine hot section materials and decreasing weight of fan section of the engine. NASA is currently developing several advanced hot section materials for increasing temperature capability of future gas turbine engines. The materials of interest include ceramic matrix composites with 1482 - 1648 C temperature capability, advanced disk alloys with 815 C capability, and low conductivity thermal barrier coatings with erosion resistance. The presentation will provide an overview of durability challenges with emphasis on the environmental factors affecting durability for the next generation of gas turbine engine materials. The environmental factors include gaseous atmosphere in gas turbine engines, molten salt and glass deposits from airborne contaminants, impact from foreign object damage, and erosion from ingestion of small particles.

Misra, Ajay K.↗
DOE OSTI2023

Cooled Gas Turbine and Combined Cycle Analysis for H 2 -CH 4 Fuel Mixes (Up to 100% H 2 )

In this study, a cooled gas turbine analysis was conducted for varying levels of hydrogen (H 2 ) blends with the natural gas. The ultimate goal is to have a gas turbine design that can be used for all the fuel blends (including 100% H 2 ) without any changes to the system. The technological developments in the cooling system, gas turbine design and materials that will be required for H 2 combustion were identified and analyzed in this study to develop an advanced gas turbine design for H 2 fuels. The study includes a combined cycle performance analysis with the H 2 fuel blends using the advanced gas turbine design developed in this study. A techno-economic analysis was conducted for analyzing the impact of the H 2 fuels on the levelized cost of electricity and cost sensitivities to fuel price and capacity factor.

03 NATURAL GAS↗
DOE OSTI2024

Cooled Gas Turbine and Combined Cycle Analysis for NH 3 -CH 4 Fuel Mixes (Up to 100% NH 3 )

In this study, a cooled gas turbine (GT) analysis was conducted for varying levels of ammonia (NH 3 ) blends with methane. The ultimate goal is to have a gas turbine design that can be used for all the fuel blends (including 100% NH 3 ) without any changes to the system. The technological developments in the cooling system, gas turbine design, and materials that will be required for NH 3 combustion were identified and analyzed in this study to develop an advanced gas turbine design for NH 3 fuels. The study includes a combined cycle performance analysis with the NH 3 fuel blends using the advanced gas turbine design developed in this study. A techno-economic analysis was conducted for analyzing the impact of the NH 3 fuels on the levelized cost of electricity and cost sensitivities to fuel price and capacity factor.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1993

Gas turbine system simulation: An object-oriented approach

A prototype gas turbine engine simulation has been developed that offers a generalized framework for the simulation of engines subject to steady-state and transient operating conditions. The prototype is in preliminary form, but it successfully demonstrates the viability of an object-oriented approach for generalized simulation applications. Although object oriented programming languages are-relative to FORTRAN-somewhat austere, it is proposed that gas turbine simulations of an interdisciplinary nature will benefit significantly in terms of code reliability, maintainability, and manageability. This report elucidates specific gas turbine simulation obstacles that an object-oriented framework can overcome and describes the opportunity for interdisciplinary simulation that the approach offers.

Drummond, Colin K.↗
NASA NTRS1978

Gas turbine project status

The state-of-the-art of automobile gas turbine technology, particularly with respect to fuel economy and emissions, was defined. An advanced gas turbine system is proposed which incorporates significant advances in technology, and has a fifty to sixty percent gain in fuel economy over the spark ignition engine, while meeting the same goals of the improved gas turbine engine.

Goette, W. E.↗
DOE OSTI2020

DICE-gas turbine compound reheat combined cycle

Coal-fired Direct Injection Carbon Engine – Gas Turbine (DICE-GT) Compound-Reheat Combined Cycle (CRCC), is a combined cycle power plant comprising a multiplicity of coal-fired reciprocating internal combustion engines (RICE), which is commonly referred to by the acronym DICE (Direct Injection Carbon Engine); a natural gas-fired gas turbine (turbine and combustor); a heat recovery steam generator (HRSG); a steam turbine generator; and an integrally geared and intercooled centrifugal air compressor. Finally, the concept uses coal-water slurry/fluid in the DICE and natural gas (or hydrogen) in the gas turbine for unmatched efficiency (well above 50% net LHV) and modularity (block sizes of 120, 240 and 360 MW) with easy adaptability to carbon capture and sequestration with minimal additional cost, complexity and performance hit.

42 ENGINEERING↗
NASA NTRS1981

Development of a high-temperature durable catalyst for use in catalytic combustors for advanced automotive gas turbine engines

Durable catalytic reactors for advanced gas turbine engines were developed. Objectives were: to evaluate furnace aging as a cost effective catalytic reactor screening test, measure reactor degradation as a function of furnace aging, demonstrate 1,000 hours of combustion durability, and define a catalytic reactor system with a high probability of successful integration into an automotive gas turbine engine. Fourteen different catalytic reactor concepts were evaluated, leading to the selection of one for a durability combustion test with diesel fuel for combustion conditions. Eight additional catalytic reactors were evaluated and one of these was successfully combustion tested on propane fuel. This durability reactor used graded cell honeycombs and a combination of noble metal and metal oxide catalysts. The reactor was catalytically active and structurally sound at the end of the durability test.

Tong, H.↗
NASA NTRS1978

Cold-air performance of the compressor-drive turbine of the Department of Energy baseline automobile gas-turbine engine

The aerodynamic performance of the compressor-drive turbine of the DOE baseline gas-turbine engine was determined over a range of pressure ratios and speeds. In addition, static pressures were measured in the diffusing transition duct located immediately downstream of the turbine. Results are presented in terms of mass flow, torque, specific work, and efficiency for the turbine and in terms of pressure recovery and effectiveness for the transition duct.

Roelke, R. J.↗
NASA NTRS1986

Detonation wave compression in gas turbines

A study was made of the concept of augmenting the performance of low pressure ratio gas turbines by detonation wave compression of part of the flow. The concept exploits the constant volume heat release of detonation waves to increase the efficiency of the Brayton cycle. In the models studied, a fraction of the compressor output was channeled into detonation ducts where it was processed by transient transverse detonation waves. Gas dynamic studies determined the maximum cycling frequency of detonation ducts, proved that upstream propagation of pressure pulses represented no problems and determined the variations of detonation duct output with time. Mixing and wave compression were used to recombine the combustor and detonation duct flows and a concept for a spiral collector to further smooth the pressure and temperature pulses was presented as an optional component. The best performance was obtained with a single firing of the ducts so that the flow could be re-established before the next detonation was initiated. At the optimum conditions of maximum frequency of the detonation ducts, the gas turbine efficiency was found to be 45 percent while that of a corresponding pressure ratio 5 conventional gas turbine was only 26%. Comparable improvements in specific fuel consumption data were found for gas turbines operating as jet engines, turbofans, and shaft output machines. Direct use of the detonation duct output for jet propulsion proved unsatisfactory. Careful analysis of the models of the fluid flow phenomena led to the conclusion that even more elaborate calculations would not diminish the uncertainties in the analysis of the system. Feasibility of the concept to work as an engine now requires validation in an engineering laboratory experiment.

Wortman, A.↗
NASA NTRS1977

The effect of ambient conditions on carbon monoxide emissions from an idling gas turbine combustor

A test program employing a gas turbine combustor is outlined; the results of which quantize the effects of changes in ambient temperature and humidity on carbon monoxide emissions at simulated idle operating conditions. A comparison of the experimental results with analytical results generated by a kinetic model of the combustion process, and reflecting changing ambient conditions, is given. It is demonstrated that for a complete range of possible ambient variations, significant changes do occur in the amount of carbon monoxide emitted by a gas turbine at idle, and that the analytical model is reasonably successful in predicting changes.

Subramanian, A. K.↗
DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limits. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Coherence between internal and external noise generated by gas turbine combustors

Experiments and analysis on a gas turbine combustor unit are reported with a view in mind to separate propagated acoustic power from non-propagating 'pseudo-sound'. Analytically, it is suggested that a transition frequency will exist below which the interior pressure fluctuations are non-propagating, whereas above this frequency, of the order of 100 Hz, the noise is dominated by propagating acoustic waves. Coherence measurements are reported which show this concept to be borne out experimentally. Coherence between interior and exterior microphones is measured over a wide range of experimental conditions for a gas turbine combustor exhausting directly to the atmosphere. The purpose is to show that below a certain frequency, measurements of interior noise are not indicative of combustion noise ultimately propagating from an engine.

Strahle, W. C.↗
NASA NTRS1992

Dynamic simulation of compressor and gas turbine performance

Dynamic simulation of compressor and gas turbine performance is useful in a variety of design, analysis, and test applications. Mathematical models employing estimated or experimentally-derived component characteristics have been widely used, especially for near-design-point studies of acceleration and deceleration transients and control strategies. With recent progress in simulation methods and computational power, it has become possible to build models with detail at the stage level, and with fundamental fluid mechanics input. Such models are more useful because of the ability to study the details of inter-component flow property behavior during machine transients, even including stall and surge. Dynamic performance simulation models are discussed with emphasis on the fundamental principles of the models and the methods used to represent component and stage flow characteristics. Results of several simulations of the dynamic behavior of multistage compressors are shown with comparisons to experimental data. Possibilities for advanced computational techniques for near-real-time simulations of compressors and gas turbines are reviewed.

Walter F O'Brien↗
NASA NTRS1982

The AGT 101 advanced automotive gas turbine

A development program is described whose goal is the accumulation of the technology base needed by the U.S. automotive industry for the production of automotive gas turbine powertrains. Such gas turbine designs must exhibit reduced fuel consumption, a multi-fuel capability, and low exhaust emissions. The AGT101 powertrain described is a 74.6 kW, regenerated single-shaft gas turbine, operating at a maximum inlet temperature of 1644 K and coupled to a split differential gearbox and automatic overdrive transmission. The engine's single stage centrifugal compressor and single stage radial inflow turbine are mounted on a common shaft, and will operate at a maximum rotor speed of 100,000 rpm. All high temperature components, including the turbine rotor, are ceramic.

Rackley, R. A.↗