Search Results (507)

As turbine entry temperatures of modern jet engines continue to increase, additional thermal stresses are introduced onto the high-pressure turbine rotors, which are already burdened by substantial levels of centrifugal and gas loads. Usually, for modern turbofan engines, the temperature distribution upstream of the high-pressure stator is characterized by a series of high-temperature regions, determined by the circumferential arrangement of the combustor burners. The position of these high-temperature regions, both radially and circumferentially in relation to the high-pressure stator arrangement, can have a strong impact on their subsequent migration through the high-pressure stage. Therefore, for a given amount of thermal power entering the turbine, a significant reduction in maximum rotor temperatures can be achieved by adjusting the inlet temperature distribution. This paper is aimed at mitigating the maximum surface temperatures on a high-pressure turbine rotor from a modern commercial turbofan engine by conducting a parametric analysis and optimization of the inlet temperature field. The parameters considered for this study are the circumferential position of the high-temperature spots, and the overall bias of the temperature distribution in the radial direction. High-fidelity unsteady (phase-lag) and conjugate heat transfer simulations are performed to evaluate the effects of inlet clocking and radial bias on rotor metal temperatures. The optimized inlet distribution achieved a 100 K reduction in peak high-pressure rotor temperatures and 7.5% lower peak temperatures on the high-pressure stator vanes. Furthermore, the optimized temperature distribution is also characterized by a significantly more uniform heat load allocation on the stator vanes, when compared to the baseline one. Full article

Gas turbine engines have several advantages over piston reciprocating engines, such as higher output per unit volume, reduced vibration, rapid acceleration and deceleration, high power output, and clean exhaust gases. As a result, their use for propulsion in ships has been steadily increasing. However, gas turbine engines exhibit significant parameter variations depending on the rotational speed, making the design of controllers to ensure system stability while achieving satisfactory control performance, a very challenging task. In this paper, a novel CEM-based 2-DOF PID controller design technique is proposed to ensure the stability of a gas turbine engine while improving tracking and disturbance rejection performance. The proposed controller consists of a PID controller focused on enhancing disturbance rejection performance and a set-point filter to improve tracking performance. The set-point filter is composed of gains from the controller and a single weighting factor. When tuning the gains of the controller, the maximum sensitivity is considered to maintain an appropriate balance between system stability and response performance. The key novelty of this study can be summarized in two main points. One is that the controller is designed by matching characteristic equations, and by setting the roots of the desired characteristic equation as multipoles, the gains of the PID controller can be tuned with only one adjusting variable, making the tuning of the 2-DOF controller easier. The other is that the controller parameters are tuned based on maximum sensitivity, thus taking into account the robust stability of the control system. To demonstrate the feasibility of the proposed method, simulations are conducted for four scenarios using various performance indices. Full article

Effusion cooling is often regarded as one of the critical techniques to protect solid surfaces from exposure to extremely hot environments, such as inside a combustion chamber where temperature can well exceed the metal melting point. Designing such efficient cooling features relies on thorough understanding of the underlying flow physics for the given engineering scenarios, where physical testing may not be feasible or even possible. Inevitably, under these circumstances, modelling and numerical simulation become the primary predictive tools. This review aims to give a broad coverage of the numerical methods for effusion cooling, ranging from the empirical models (often based on first principles and conservation laws) for solving the Reynolds-Averaged Navier–Stokes (RANS) equations to higher-fidelity methods such as Large-Eddy Simulation (LES) and hybrid RANS-LES, including Detached-Eddy Simulation (DES). We also highlight the latest progress in machine learning-aided and data-driven RANS approaches, which have gained a lot of momentum recently. They, in turn, take advantage of the higher-fidelity eddy-resolving datasets performed by, for example, LES or DES. The main examples of this review are focused on the applications primarily related to internal flows of gas turbine engines. Full article

This paper presents the results of an analysis of resistance to hydrogen embrittlement and offers solutions and technologies for manufacturing castings of components for critical applications, such as blades for gas turbine engines (GTEs). The values of the technological parameters for directional crystallization (DC) are determined, allowing the production of castings with a regular dendritic structure of the crystallization front in the range of 10 to 12 mm/min and a temperature gradient at the crystallization front in the range of 165–175 °C/cm. The technological process of making GTE blades has been improved by using a scheme for obtaining disposable models of complex profile castings with the use of 3D printing for the manufacture of ceramic molds. The ceramic mold is obtained through an environmentally friendly technology using water-based binders. Short-term tensile testing of the samples in gaseous hydrogen revealed high hydrogen resistance of the CM-88 alloy produced by directed crystallization technology: the relative elongation in hydrogen at a pressure of 30 MPa increased from 2% for the commercial alloy to 8% for the experimental single-crystal alloy. Full article

The objective of this study is to implement a more realistic integrated analysis model for micro gas turbines by incorporating secondary flow and combustion efficiency into the existing model, which includes main engine components such as the compressor and turbine, and to validate this model by comparing it with test results. The study was based on the JetCat P300-RX, which has a maximum thrust level of 300 N. Simulations were performed using ANSYS CFX, employing the κ-ω SST turbulence model and a mixing plane interface between individual components. The eddy dissipation model (EDM), with a combustion efficiency of 90%, was used as the combustion model. A user subroutine was also applied for the power matching of the compressor and turbine to calculate the fuel flow rate in each iteration. For secondary flow, it was assumed that 3% of the total air flow rate would flow through the secondary path and be applied to the compressor and turbine. Simulations were conducted over a range of 30,000 to 104,000 RPM, with ground conditions evaluated, including altitude-simulated conditions. To validate the analysis model, engine performance metrics such as pressure ratio, air flow rate, fuel flow rate, and exhaust gas temperature (EGT) were compared with test results. The results demonstrated that errors were less than 5% for most engine performance metrics, except for EGT and fuel flow. The discrepancy in EGT was attributed to differences in the sensing methods, while the variation in fuel flow was found to be due to the lubrication system and losses due to the secondary air flow. Consequently, this study confirmed that the integrated simulation model accurately predicts engine performance. The results indicate that the integrated simulation model provides a more realistic prediction of overall engine performance compared to previous studies. Therefore, it can evaluate detailed thermo-fluid properties without the need for component performance maps, enhancing performance evaluation and analysis. Full article

Due to increasing emissions and global warming, in parallel with the increasing world population and energy needs, IMO has introduced severe rules for ships. Energy efficiency on ships can be achieved using the organic and inorganic Rankine cycle (RC) driven by exhaust heat from marine diesel engines. In this study, toluene, R600, isopentane, and n-hexane as dry fluids; R717 and R718 as wet fluids; and R123, R142b, R600a, R245fa, and R141b as isentropic fluids are selected as the working fluid because they are commonly used refrigerants, with favorable thermal properties, zero ODP, low GWP and are good contenders for this application. The cycle and exergy efficiencies, net power, and irreversibility of marine diesel engine exhaust-driven simple RC and RC with a recuperator are calculated. For dry fluids, the most efficient fluid at low turbine inlet temperatures is n-hexane at 39.75%, while at high turbine inlet temperatures, it is toluene at 41.20%. For isentropic fluids, the most efficient fluid at low turbine inlet temperatures is R123 with 23%, while at high turbine inlet temperatures it is R141b with 23%. As an inorganic fluid, R718 is one of the most suitable working fluids at high turbine inlet temperatures of 300 °C onboard ships with a safety group classification of A1, ODP of 0, and GWP100 of 0, with a cycle efficiency of 33%. This study contributes to significant improvements in fuel efficiency and reductions in greenhouse gas emissions, leading to more sustainable and cost-effective maritime operations. Full article

The problem of increasing heat resistance and corrosion and erosion resistance of gas turbine units in compressor stations was solved through the development of new layered materials containing nanostructured grains. The authors carried out a destruction analysis of gas turbine units in compressor stations. It was shown that after 10–30,000 h of operation, the greatest damage occurred when the gas turbine operated in dusty environments at high temperatures (or in air environments with a high salt content). The developed layered composites include the thermal barrier and functional reinforced nanostructured layers consisting of refractory carbides and oxides. This paper describes the destruction mechanism of gas turbine units under the influence of high-temperature aggressive environments. As a result, a new formation technology for reinforced nanostructured layered composites has been developed. The developed composition makes it possible to increase the heat resistance of materials by approximately 10 times. This significantly increases the reliability and durability of gas turbine units in compressor stations. The structural and mechanical parameters of the layered nanostructured heat-resistant composites have been studied. Full article

Day after day, stricter environmental regulations and rising operating costs and fuel prices are forcing the shipping industry to find more effective ways of designing and operating energy-efficient ships. One of the ways to produce electricity efficiently is to create a waste heat-driven liquid metal–water binary vapor power plant. The liquid metal Rankine cycle systems could be considered topping cycles. Liquid metal binary cycles share characteristics like those of the steam Rankine power plants. They have the potential for high conversion efficiency, they will likely produce lower-cost power in plants of large capacity rather than small, and they will operate more efficiently at design capacity rather than at partial load. As a result, liquid metal topping cycles may find application primarily as base-load plants onboard ships. In this study, a waste heat-driven liquid metal–water binary vapor power plant onboard a ship is designed and thermodynamically analyzed. The waste heat onboard the vessel is the exhaust gas of the LM2500 marine gas turbine. Mercury and Cesium are selected as liquid metals in the topping cycle, while water is used in the bottoming cycle in binary power plants. Engineering Equation Solver (EES) software (V11.898) is used to perform analyses. For the turbine inlet temperature of 550 °C, while the total net work output of the binary cycle system is calculated to be 104.84 kJ/kg liquid metal and 1740.29 kJ/kg liquid metal for mercury and cesium, respectively, the efficiency of the binary cycle system is calculated to be 31.9% and 26.3% for mercury and cesium as liquid metal, respectively. This study shows that the binary cycle has a thermal efficiency of 26.32% and 31.91% for cesium and mercury, respectively, depending on liquid metal condensing pressure, and a binary cycle thermal efficiency of 25.9% and 30.9% for cesium and mercury, respectively, depending on liquid metal turbine inlet temperature, and these are possible with marine engine waste heat-driven liquid metal–water binary vapor cycles. Full article

This study explores the intersection of waste management and sustainable fuel production, focusing on the pyrolysis of plastic waste, specifically polystyrene. We examine the physicochemical parameters of the resulting waste plastic pyrolytic oils (WPPOs), blended with kerosene to form a potential alternative fuel for gas turbines. Our findings reveal that all WPPO blends lead to increased emissions, with NO_X rising by an average of 61% and CO by 25%. Increasing the proportion of WPPO also resulted in a higher exhaust gas temperature, with an average rise of 12.2%. However, the thrust-specific fuel consumption (TSFC) decreased by an average of 13.8%, impacting the overall efficiency of waste-derived fuels. This study underscores the need for integrated waste-to-energy systems, bridging the gap between waste management and resource utilization. Full article

Higher operating temperatures for gas turbine engines require highly durable thermal barrier coatings (TBCs) with improved insulation properties. A suspension plasma spray process (SPS) had been developed for the deposition of columnar-structured TBCs. SPS columnar TBCs are normally achieved at a short standoff distance (50.0 mm–75.0 mm), which is not practical when coating complex-shaped engine hardware since the plasma torch may collide with the components being sprayed. Therefore, it is critical to develop SPS columnar TBCs at longer standoff distances. In this work, a commercially available pressure-based suspension delivery system was used to deliver the suspension to the plasma jet, and a high-enthalpy TriplexPro-210 plasma torch was used for the SPS coating deposition. Suspension injection pressure was optimized to maximize the number of droplets injected into the hot plasma core and achieving the best particle-melting states and deposition efficiency. The highest deposition efficiency of 51% was achieved at 0.34 MPa injection pressure with a suspension flow rate of 31.0 g/min. With the optimized process parameters, 1000 μm thick columnar-structured SPS 8 wt% Y₂O₃-stabilized ZrO₂ (8YSZ) TBCs were successfully developed at a standoff distance of 100.0 mm. The SPS TBCs have a columnar width between 100 μm and 300 μm with a porosity of ~22%. Furnace cycling tests at 1125 °C showed the SPS columnar TBCs had an average life of 1012 cycles, which is ~2.5 times that of reference air-plasma-sprayed dense vertically cracked TBCs with the same coating thickness. The superior durability of the SPS columnar TBCs can be attributed to the high-strain-tolerant microstructure. SEM cross-section characterization indicated the failure of the SPS TBCs occurred at the ceramic top coat and thermally grown oxide (TGO) interface. Full article

This paper presents a detailed study on the main parameters and performance evaluation of microjet engines, at take-off regime and at various engine working regimes, based on thermodynamic analysis of a particular engine data library, from different engine manufacturers such as JetCat and AMT Netherlands. The studied engines have the same spool design but different thrust classes ranging from 97 to 1569 N. The particular data library includes engine specifications from catalogs or data sheets as well as our own experimental data from the JetCat P80 microjet engine, obtained using the ET 796 Jet Turbine Module, a complete testing facility for gas turbine education purposes. Various ratios and differences between certain engine main parameters and performances are studied in order to calculate values through which the analyses can be performed. Even if the engines have different thrust classes, the study examines if there are close values of the ratios and differences of parameters, that can be defined as reference parameters through which the engine performance can be compared and evaluated. Full article

Identifying and analyzing the engine performance and emission characteristics under the condition of performance decay is of significant reference value for fault diagnosis, condition-based maintenance, and health status monitoring. However, there is a lack of relevant research on the currently popular marine large two-stroke dual fuel (DF) engines. To fill the research gap, a detailed zero-/one-dimensional (0D/1D) model of a marine two-stroke DF engine employing the low-pressure gas concept is first established in GT-Power (Version 2020) and validated by comparing the simulation and measured results. Then, three typical types of turbocharger performance decays are defined including turbine efficiency decay, turbine nozzle ring area decay, and turbocharger shaft mechanical efficiency decay. Finally, the three types of decays are introduced to the engine simulation model and parametric runs are performed in both diesel and gas modes to identify and analyze their impacts on the performance and emission characteristics of the investigated marine DF engine. The results reveal that turbocharger performance decay has a significant impact on engine performance parameters, such as brake efficiency, engine speed, boost pressure, etc., as well as CO₂ and NOx emissions, and the specified limit value on certain engine operational parameters will be exceeded when turbocharger performance decays to a certain extent. The changing trend of engine performance and emission parameters as turbocharger performance deteriorates are generally consistent in both operating modes but with significant differences in the extent and magnitude, mainly due to the distinct combustion process (Diesel cycle versus Otto cycle). Furthermore, considering the relative decline in brake efficiency, engine speed drop, and relative increase in CO₂ emission, the investigated engine is less sensitive to the turbocharger performance decay in gas mode. The simulation results also imply that employing a variable geometry turbine (VGT) is capable of improving the brake efficiency of the investigated marine DF engine. Full article

This paper addresses the critical issue of turbine blade containment in aircraft engines, crucial for ensuring flight safety. Through a comprehensive approach integrating numerical simulations and experimental validations, the containment capabilities of gas turbine engine casings are thoroughly analyzed. The study investigates the impact dynamics, deformation characteristics, and energy absorption mechanisms during blade detachment events, shedding light on the containment process. Based on the multi-stage nature of gas turbines, two different blade structures were designed for turbine blades. Utilizing finite element simulation and the Johnson–Cook constitutive equation, this study accurately simulated single-blade and dual-blade containment scenarios. The simulation results of the single blade indicate that the process of a gas turbine blade impacting the casing primarily consists of three stages. The second stage, where the tenon root strikes the casing, is identified as the main cause of casing damage. Meanwhile, in the dual-blade simulation, the second blade, influenced by the first blade, directly impacts the casing after fracturing, resulting in greater damage. Then, eight corresponding containment tests were conducted based on the simulation results, validating the accuracy of the simulation parameters. Experimental verification of simulation results further confirms the validity of the proposed containment curves, providing essential insights for optimizing casing design and enhancing the safety and reliability of aircraft engines. Full article

The paper presents conclusions from research conducted at the Warsaw University of Technology in 2019–2023 regarding the combustion of fuel–water emulsions in a miniature gas turbine. The presented conclusions were made taking the current state of knowledge available in the literature into account. Particular emphasis was placed on explaining the discrepancies in the results of the experimental studies available in the literature. The main aspects of the combustion of the fuel–water emulsions that were analyzed were their impact on the emissions of NOx and CO, as well as the impact of the surfactant included in the fuel mixture on the combustion process, emissions and the formation of deposits on the walls of the combustion chamber. The impact of the emulsion fuel on fuel consumption was also discussed. In order to explain the changes occurring in the combustion chamber as a result of adding water to the fuel, numerical methods and methods of fluid mechanics were used. Studies have shown a positive impact of the use of fuel–water emulsions on CO and NOx emissions and fuel consumption. It was also demonstrated that fuel additives used for emulsification can create deposits on the walls of the hot engine section. Full article