NASA Technical Reports Server (NTRS) 20150004423: Compact Gas Turbine Sub-Project - TC 4.2 Compact, High Overall Pressure Ratio (OPR 50+) Gas Generator

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by  NASA Technical Reports Server (NTRS)

Advanced Air Transport Technology Project (AATT)(cid:1)

Compact Gas Turbine Sub-Project(cid:1)
(cid:1)
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TC 4.2 Compact, High Overall Pressure Ratio(cid:1)
(OPR 50+) Gas Generator(cid:1)
(cid:1)
(cid:1)
Michael D. Hathaway(cid:1)
Technical Lead(cid:1)
(cid:1)
(cid:1)
(cid:1)
Icing Hazards Workshop(cid:1)
January 28-29, 2015(cid:1)
NASA Glenn Research Center(cid:1)
Advanced Air Transport Technology Project(cid:1)
Advanced Air Vehicle Program(cid:1) 1
Compact GT Subproject (cid:1)
Future propulsion systems will be of increasingly higher bypass
ratio from larger fans combined with much smaller cores(cid:1)

AATT TC 4.2 Compact, High Overall Pressure Ratio (OPR 50+) Gas Generator
Enable reduced size/flow high pressure compressors and high 1500F temperature disk/seals
for gas generators with 50+ OPR with minimal impact on noise and component life (TRL4)
(cid:1)
Technical Challenge Investments(cid:1)
•  Hot Section Materials ( incl: Hybrid Disk & High Temp Seals)(cid:1)
•  Reduced Size/Flow HPC Technologies & Concept(s) Development(cid:1)
(cid:1)
Emerging TC Investments(cid:1)
•  Adaptive Fan Blade (incl Shape Memory Alloy & Toughened Fan Blade )(cid:1)
•  Active Tip Clearance Control: Planning Effort with go/no-go start in FY16(cid:1)
(cid:1)
Advanced Air Transport Technology Project(cid:1)
Advanced Air Vehicle Program(cid:1) 2
TC4.2(FY19): Compact, High Overall Pressure Ratio
(cid:1) (cid:1) (cid:1) (cid:1) (OPR 50+) Gas Generator, TRL 4
(cid:1)
Objective (cid:1) Aero Struc Prop Clean Quiet
Develop critical technologies to enable reduced size/flow gas
generators with 50+ OPR and disk/seal temperatures of 1500F
with minimal impact on noise and component life (TRL4).(cid:1)
(cid:1)
ducted fan open fan hybrid system
Technical Areas and Approaches(cid:1)
Hot Section Materials(cid:1)
–  1500F disk & coatings(cid:1)
materials, aerodynamics,
–  1500F capable non-contacting seal(cid:1)
and contro l
High Pressure Compressor Technologies(cid:1)
–  P&W NRA: system study, compressor design to
mitigate losses, design/fab/testing, casing treatment if
needed(cid:1)
–  GE NRA: system study, existing N+3 relevant 1500 F, bonded
hybrid disk
compressor hardware, low/high speed tests of casing
concept
treatment with large tip gap blading(cid:1)
High Pressure Turbine Technologies(cid:1)
–  Developing plan(cid:1)
Tip/endwal l
Benefit/Pay-off(cid:1)
aerodynamic
–  Advanced compact gas-generator core architecture and loss mitigation
component technologies enabling BPR 20+ growth by
minimizing core size(cid:1)
A–dv  aTnchede Armir Tarallnys peofrfit Tceiechnnto,l ohgiyg Phro OjecPt(cid:1)R (50+)(cid:1)
Advanced Air Vehicle Program(cid:1) 3
TC 4.2: Disk Alloy Coatings To Mitigate Hot Corrosion(cid:1)
Problem(cid:1)
Higher disk operating temperatures lead to oxidation and hot corrosion --
strongly degrading low cycle fatigue (LCF) life.(cid:1)
Objective(cid:1)
Develop oxidation/hot corrosion resistant coatings that maintain most of
uncoated LCF life.(cid:1)
Fatigue Bars in plasma enhanced magnetron (cid:1)
Approach(cid:1)
sputtering (PEMS) coater at vendor(cid:1)
Apply high chromium coatings, initially by sputtering, onto disk-alloy
LCF test bars. Compare lives before and after exposure: oxidation and
low temperature hot corrosion (LTHC) at 1400°(cid:1)
Results(cid:1)
•  Disk alloy bars coated with Ni-45%Cr-Y (1mil thickness, peened, pre-
oxidized, exposed to oxidation and LTHC) maintained over 70% of the
fatigue life of baseline samples (uncoated). (cid:1)
•  Reducing the coating flaws via substrate surface modification and
high impulse sputtering will be the next steps in producing an
environmentally protective coating.(cid:1)
Significance(cid:1)
High %Cr coatings greatly improve the performance of disk alloys after
oxidation and LTHC, and is a key technology for disk alloy material concepts
to enable High OPR (40+) gas generator core for fuel burn benefits. Paths to
further improvements identified.(cid:1)
Higher Cr coating retain over 50% of uncoated/
Research Team: Robert Miller, Tim Gabb, Jack Telesman, Sue Draper, & Chantal Sudbrack (GRC, LMA)
unexposed LCF life after 500 hrs oxidation/
50 hrs LTHC at 1400°°F
Advanced Air Transport Technology Project(cid:1)
Advanced Air Vehicle Program(cid:1) 4
TC 4.2: Small Core Size Design Challenge for High
OPR Engine(cid:1)
Problem(cid:1)
Enable high OPR (40+) gas generator core for improved thermal
efficiency and fuel burn reduction(cid:1)
Objective(cid:1)
Mitigate aerodynamic losses and resulting decrements in high
OPR core compressor and turbine efficiencies due to larger tip
clearance and under-platform seal cavity gaps associated with
small core size.(cid:1)
Approach(cid:1)
Compressor (cid:1)
Solicit NRA proposals for N+3 relevant system studies of high
exit corrected flow W √ θ (cid:1)(cid:1) 6.0 lbm/s vs. (cid:1)
OPR core to assess benefits and develop concepts, approaches, δ(cid:1)
“core size” (cid:1) 2.0 lbm/s core size(cid:1)
and roadmaps to substantiate potential performance and fuel
burn benefits of proposed technologies, and then down-select
(cid:1)
n
most promising concept(s) for TRL 4 testing.(cid:1) a
p
4x %(cid:1) 2XSOA(cid:1)S
Results(cid:1)
(cid:1) e
e d
NRAs awarded to GE for an advanced casing treatment ancss(cid:1) Low clearance(cid:1) Bla
ro /
concept applied to an advanced HPC aft block, and to P&W aL small cores(cid:1) p
e a
ly G
for a conceptual and preliminary design of a HPC tied to N+3 Cnc 2x % Current SOA cores(cid:1) SOA(cid:1) e
pe c
relevant system studies, followed by low and high speed tests e Tifici ran
of candidate blade design and technology concepts in a agEf ea
St Cl
scaled HPC aft block commensurate with manufacturing 0.0 % 0.0 %(cid:1) p
i
limitations of small core blade.(cid:1) 0(cid:1) 10(cid:1) 20(cid:1) T
Stage Corrected Flow (lbm/s)(cid:1)
Significance(cid:1)
TRL 4 demonstration of benefits afforded by high OPR small core
engine concept anchored by N+3 relevant system studies.(cid:1)
(cid:1)
Research team: Chunill Hah (COTR, P&W NRA, NASA GRC) , Vikram Shyam (COTR, GE NRA, NASA GRC)
Advanced Air Transport Technology Project(cid:1)
Advanced Air Vehicle Program(cid:1) 5
FY14 Progress and Accomplishments(cid:1)
•  Completed hybrid disk coating studies (GRC)(cid:1)
•  Second round hybrid turbine disk linear friction weld trials demonstrated significant bond
improvement; no porosity, no secondary phase and no Al2O3 particle contamination at
the bond interface (GRC)(cid:1)
•  Conducted room temperature static and bind-up tests of a baseline non-contacting
finger seal GRC)(cid:1)
•  Conducted in-house and funded work to define potential high efficiency small core
architectures (GRC)(cid:1)
•  Prepared a report examining historical development of technology affecting gas turbine
engine fuel economy (GRC)(cid:1)
•  Completed Particle Image Velocimetry and Focused Schlieren tests of long hole film
cooling resulting in comprehensive benchmark data set for CFD validation (GRC)(cid:1)
•  Assessed aerodynamic impact of shaped film cooling holes on a PW HPT blade (under
SAA) including flowfield, film effectiveness, and boundary layer measurements (GRC)(cid:1)
•  Showed significant improvement to composite damage tolerance using the
thermoplastic interleave approach for toughened composite blade (GRC) (cid:1)
•  Developed finite element modeling methodology for analysis and failure predictions of
adhesively bonded joints of shape memory alloy (SMA) ribbon and polymer matrix
composite (PMC) substrates system structures for adaptive composite fan blade shape
change concept (GRC)(cid:1)
•  All turbomachinery tip clearance/endwall loss NRA’s requested short no-cost extensions
to complete experiments and documentation (NRA’s)(cid:1)
Advanced Air Transport Technology Project(cid:1)
Advanced Air Vehicle Program(cid:1) 6