Search Results (56)

The application of thermal barrier coatings (TBCs) for protecting mechanical components is widespread, particularly in high-temperature environments, such as gas turbines and aero-engines. Ensuring the integrity of these coatings throughout their service life is essential, as their degradation can lead to delamination, ultimately compromising the underlying component. It has been demonstrated that monitoring the thermal diffusivity value over time allows the monitoring of degradation of the coatings. Common thermographic techniques like pulsed and lock-in thermography have been used so far. However, to enhance both the signal-to-noise ratio (SNR) and the accuracy of thermal property measurements, new active thermography techniques have been developed. These methods rely on optimized excitation schemes combined with advanced signal processing strategies. In this work, we first introduce the pulse-compression thermography approach, which employs pseudo-noise modulated excitation to monitor and estimate the thermal diffusivity of the coating layers. Full article

Altitude Test Facility (ATF) compressor systems are widely used in aero-engine tests. These systems achieve the control of gas pressure and transport through complex operation processes. With advancements in the aviation industry, there is a growing demand for higher performance, greater safety, and more energy efficiency in digital ATF systems. Hybrid modeling is a technology that combines many methods and can meet these requirements. The Modular Dynamic System Greitzer (MDSG) compressor model, including mechanistic and data-driven modeling approaches, is combined with a neural network to obtain a BPNN-MDSG hybrid modeling method for the digital turbine system. The digital simulation is linked with the physical sensors of the ATF system to realize real-time simulation and monitoring. The steady and dynamic conditions of the actual system are simulated in virtual space. Compared with the actual results, the average error of steady mass flow is less than 3%, and the error of pressure is less than 1%. The average error of dynamic mass flow is less than 5%, and the error of pressure is less than 3%. The simulation and characteristic predictions are carried out in BPNN-MDSG virtual space. The anti-surge characteristics of the ATF system under start-up conditions are obtained. The full-condition anti-surge operation map of the system is obtained, which provides guidance for the actual operation of the ATF system. Full article

Based on GJB 242A, a detailed experimental procedure for the sand and dust ingestion of a turboshaft engine was established. A specific type of turboshaft engine was used to conduct 54 h full-engine sand and dust ingestion experiments. This research studied the impact of sand and dust ingestion on the engine’s common operating line, power loss, specific fuel consumption, and gas turbine exhaust temperature, among other performance parameters. The experimental results indicate that under the same equivalent power conditions, the impact of short-term sand and dust ingestion on the engine’s common operating line is minimal; as the sand and dust ingestion time increases, the equivalent airflow decreases significantly, causing the engine’s common operating line to shift upward and the gas turbine exhaust temperature to rise, with the maximum increase reaching 27.9 °C. However, the impact of sand and dust ingestion on the gas turbine exhaust temperature at high power levels is relatively small. After completing the sand and dust ingestion test, the engine’s power loss at maximum continuous operation was approximately 11.33%, and the specific fuel consumption increased by about 6.05%. The power loss does not meet the requirement of being less than 10% as stipulated in GJB 242A. Based on the engine disassembly inspection results, subsequent improvement suggestions were proposed. The findings of this paper can provide a scientific and rational basis and reference for the sand and dust resistance design and sand ingestion testing of similar aero-engines. Full article

The health monitoring system has been the main technological approach to extending the life of gas turbine engines and reducing maintenance costs resulting from performance degradation caused by asymmetric factors like carbon deposition, damage, or deformation. One of the most critical techniques within the health monitoring system is performance degradation prediction. At present, most research on degradation prediction is carried out using NASA’s open dataset, C-MAPSS, without considering that monitoring measurements are not always available, as in the ideal dataset. This limitation makes fault diagnosis algorithms and remaining useful life prediction methods difficult to apply to real gas turbine engines. Therefore, to solve the problem of performance degradation prediction in light-duty gas turbine engines, a prediction diagram is proposed based on Long Short-Term Memory (LSTM). Various types of onboard signals are taken into consideration among the experimental data. Only accumulated usage time, total temperature and total pressure before the inlet, low-pressure rotor speed, high-pressure rotor speed, fuel flow rate, exhaust temperature, and thrust are used in the training process, which is indispensable for an aero-engine. A genetic algorithm (GA) is introduced into the training process to optimize the hyperparameters of LSTM. The performance degradation prediction modeled with the GA-LSTM method is validated using experimental data. The maximum prediction error of thrust is 70 daN, and the mean absolute percentage error (MAPE) is less than 0.04. This study provides a practical approach to implementing performance degradation prediction in health monitoring systems to improve gas turbine engine reliability, economy, and environmental performance. Full article

Gas turbine engines are used in many applications such as power plants and aircrafts. The energy generated through fuel combustion has a significant impact on fluid flow characteristics and thrust force produced by gas turbine engines. This energy generation is based on the precise mixing of fuel and air with known proportions. The present research work attempts to examine the characteristics of fluid flow for aero-engine combustion in a chamber with either a single fuel inlet or multiple fuel inlets using the computational fluid dynamics (CFD) technique. Developed in Creo-6.0 parametric design software, the combustion chamber was modeled and simulated using the ANSYS CFX simulation platform to determine the pressure and other fluid flow-induced characteristics. The analysis was performed for both single fuel inlet and multiple fuel inlet combustion chamber designs. The outlet pressure of the combustion chamber is a key parameter in determining the combustion characteristics and subsequent gas expansion in gas turbine performance. Our results indicated that the outlet pressure from the double fuel inlet design was 49.04% higher than the single fuel inlet design. The thrust force (propulsion) in gas turbine engines is a result of the mass flow rate of exhaust gasses, as quantified by the gas exit velocity. Induced thrust on a combustor with double fuel inlet was 48.3% higher than the induced thrust in the single fuel inlet design, making the double fuel inlet design a more viable option. The higher outlet pressure obtained in the double fuel inlet design showed higher enthalpy generation and greater energy conversion into thrust. The cause of this higher enthalpy is attributed to better fuel combustion in the primary zone. It appears that the double fuel inlet design could improve total turbine efficiency, reduce fuel consumption, and lower emissions. Full article

For next-generation power systems, particularly aero-gas turbine engines, ultra-light and highly efficient heat exchangers are considered key enabling technologies for realizing advanced cycles. Consequently, the development of efficient and accurate aero-engine heat exchanger test equipment is essential to support future gas turbine heat exchanger advancements. This paper presents the development of a high-pressure and high-temperature (HPHT) heat exchanger test facility designed for aero-engine heat exchangers. The maximum temperature and pressure of the test facility were configured to simulate the conditions of the last-stage compressor of a large civil engine, specifically 1000 K and 5.5 MPa. These conditions were achieved using multiple electric heater systems in conjunction with an air compression system consisting of three turbo compressor units and a reciprocating compressor unit. A commissioning test was conducted using a compact tubular heat exchanger, and the results indicate that the test facility operates stably and that the measured data closely align with the predicted performance of the heat exchanger. A commissioning test of the tubular heat exchanger showed a thermal imbalance of 1.02% between the high-pressure (HP) and low-pressure (LP) lines. This level of imbalance is consistent with the ISO standard uncertainty of ±2.3% for heat dissipation. In addition, CFD simulation results indicated an average deviation of approximately 1.4% in the low-pressure outlet temperature. The close alignment between experimental and CFD results confirms the theoretical reliability of the test bench. The HPHT thermal performance test facility will be expected to serve as a critical test bed for evaluating heat exchangers for current and future gas turbine applications. Full article

Dynamic compressors are widely used in many industrial sectors, such as air, land, and marine vehicle engines, aircraft environmental control systems (ECS), air-conditioning and refrigeration, gas turbines, gas compression and injection, etc. The data-driven formulas of mass flow rate and isentropic efficiency of dynamic compressors are required for the design, energy analysis, performance simulation, and control- and/or diagnosis-oriented dynamic simulation of such compressors and the related systems. This work develops data-driven models for predicting the performance of dynamic compressors, including empirical models for mass flow rate and isentropic efficiency, which have high prediction accuracy and broad application range. The performance maps of two multi-stage axial compressors of an aero engine and a centrifugal compressor of an aircraft ECS were chosen for evaluation of the existing empirical formulas and testing of the new models. There are 16 empirical models of mass flow rate and 14 empirical models of isentropic efficiency evaluated, and the results show that it is necessary to develop highly accurate empirical formulas both for mass flow rate and isentropic efficiency. With the data-driven method, two empirical models for mass flow rate and one for isentropic efficiency are developed. They are in general form, with some terms removable to make them simple while enhancing their applicability and prediction accuracy. The new models have much higher prediction accuracy than the best existing counterparts. The new mass flow rate models predict for the three compressors a mean absolute relative deviation (MAD) not greater than 1.3%, while the best existing models all have MAD > 2.0%. The new efficiency model predicts for the three compressors an MAD of 1.0%, 0.4%, and 1.9%, respectively, while the best existing model predicts for the three compressors an MAD of 1.8%, 0.8%, and 3.2%, respectively. Full article

A high-temperature-resistance single-crystal magnesium oxide (MgO) extrinsic Fabry–Perot (FP) interferometer (EFPI) fiber-optic vibration sensor is proposed and experimentally demonstrated at 1000 °C. Due to the excellent thermal properties (melting point > 2800 °C) and optical properties (transmittance ≥ 90%), MgO is chosen as the ideal material to be placed in the high-temperature testing area. The combination of wet chemical etching and direct bonding is used to construct an all-MgO sensor head, which is favorable to reduce the temperature gradient inside the sensor structure and avoid sensor failure. A temperature decoupling method is proposed to eliminate the cross-sensitivity between temperature and vibration, improving the accuracy of vibration detection. The experimental results show that the sensor is stable at 20–1000 °C and 2–20 g, with a sensitivity of 0.0073 rad (20 °C). The maximum nonlinearity error of the vibration sensor measurement after temperature decoupling is 1.17%. The sensor with a high temperature resistance and outstanding dynamic performance has the potential for applications in testing aero-engines and gas turbine engines. Full article

Transpiration cooling based on a porous structure has an ultra-high cooling efficiency, which is expected to be one solution to improve the cooling technology of aero-engine turbine blades. However, particulate impurities in the gas flow channel continue to deposit on the surface of turbine components, blocking cooling holes, which causes great harm to the cooling of turbine blades. In this study, a sintered metal mesh plate was selected as the transpiration cooling structure, and the evolution of particle deposition quality and deposition thickness on the transpiration cooling surface with time, as well as spatial distributions of particle deposition thickness at different times, were explored through experimental and simulation methods. The results showed that, with the increase in spray time, deposition quality and maximum deposition thickness of the transpiration cooling surface gradually increased. Along the main-stream direction, when spray time was short, deposition thickness was higher in a narrow range upstream of the experimental specimen. With the increase in spray time, deposition thickness gradually decreased along the direction of the transpiration cooling mainstream. In the spanwise direction, when spray time was very short, deposition thickness in the spanwise direction was more consistent and, after spray time increased further, the deposition thickness distribution began to tend to a “∩”-type distribution. It can be seen from the simulation results of the metal wire mesh particle deposition that particles were easily deposited on the windward side of the metal wire in the main-stream direction, which agreed with the experimental distribution characteristics of the metal wire mesh deposition. Moreover, the increase in blowing ratio reduced the deposition of particles on the wall of the metal wire mesh. Full article

To accurately predict the matching relationships between the various components and the engine performance in the whole aero-engine environment, this study introduces a two-dimensional throughflow simulation method for the whole aero-engine. This method is based on individual throughflow solvers for the turbo-machinery and the combustor. It establishes a throughflow simulation model for the whole engine by integrating with the compressor-turbine co-operating equations and boundary conditions. The turbo-machinery throughflow solver employs a circumferentially averaged form of the time-dependent Navier–Stokes equations (N-S) as the governing equation. The combustor solver uses the Reynolds Average Navier–Stokes (RANS) method to solve flow and chemical reaction processes by constructing turbulence, combustion, and radiation models. The accuracy of the component solver is validated using Pratt and Whitney’s three-stage axial compressor (P&W3S1) and General Electric’s high-pressure turbine (GE-EEE HPT), and the predicted results are consistent with the experimental data. Finally, the developed throughflow method is applied to simulate the throttling characteristics of the WZ-X turboshaft engine. The results predicted by the throughflow program are consistent with the GasTurb calculations, including the trends of shaft power delivered, specific fuel consumption (SFC), inlet airflow, and total pressure ratio of the compressor. The developed method to perform throughflow simulation of the whole aero-engine eliminates the dependence on a general component map. It can quickly obtain the meridian flow field parameters and overall engine characteristics, which is expected to guide the design and modification of the engine in the future. Full article

Combined with the development trend of high speed generators and the high voltage of DC microgrids in high-power series hybrid aero propulsion system, a set of hybrid systems with a power of 200 kW, voltage of 540 V, and speed of 21,000 r/min is established in this article. Ground starting tests were conducted, focusing on the analysis of the coupling characteristics between the engine, generator and motors/propellers during the starting process, and further facilitated the optimization of the strategy of starting control. Firstly, the starting process of the series hybrid aero propulsion system mainly consists of four stages: the turboshaft engine is started, the gas turbine speed is increased, the controlled rectification intervenes, and the electric propeller is activated. The recommended definition of the idle state of the 200 kW hybrid propulsion system in this paper is as follows: power turbine speed N_P = 10,500 rpm, grid system voltage U_DC = 540 V, and the minimum stable power state of the electric motor P_M = 150 W. Furthermore, experiments reveal that during the starting process, the resistance value and the rectification strategy, respectively, affect the steady-state and dynamic characteristics of the power turbine speed. By comparing multiple sets of experiments and utilizing data fitting software for optimal design, the results indicate that, based on the starting strategy of no-load protection and two-step controlled rectification, the total duration of the optimized starting process is shortened by 64.7%, and the gas turbine speed is reduced by 22.7% compared to the pre-optimized state. The starting control sequence is clearer, and the optimization effect is significant. Full article

Modern gas turbines find extensive applications in aero engines, power generation, marine, and various other industries. Most numerical studies concentrate on turbine aero-thermal performance under different external conditions with vane or coupon; there are a few published results on combustor-turbine interactions. This study reveals the cooling performance of the first stage with or without coatings to provide a reference for high-performance combustors and turbine-integrated design. The results of the study show that (1) The velocity and temperature distribution inside the combustion chamber are obviously affected by the swirling flow. A central recirculation zone is formed near the central axis, and two external recirculation zones are formed between the inlet section of the combustion chamber and the fluid reattachment point. (2) Inside the combustion chamber, the flame temperature in the central recirculation zone is relatively high, and the range of the high-temperature zone expands with the increase of axial distance. Increasing the swirl number decreases the peak temperature level in the combustion chamber. (3) Under the influence of swirl number, the greater the swirl number, the greater the cooling effectiveness of most areas on the vane surface. (4) In regions where there is a decrease in local heat flux, positive values are evident. This suggests that the application of a coating in these areas results in a reduction of heat transfer from the vane to the mainstream. (5) When comparing the coated vane to the uncoated vane, the cooling effectiveness across the entire surface is notably enhanced, with a particularly significant improvement observed on the vane’s suction side. With the increase of C_ax, the difference in cooling effectiveness increment under different swirl numbers also increases. Full article

Upgrading abradable or wearable coatings in the high-temperature zone of aero engines is advised to increase the efficiency and high-density power in gas turbine engines for military or commercial fixed-wing and rotary-wing aircraft. The development of these coated materials is also motivated by minimization of the number of failures in the blade, as well as increasing their resistance to wear and erosion. It is suggested that abradable coatings or seals be used to accomplish this goal. The space between the rotor and the shroud is minimized thanks to an abradable seal at the blade’s tip. Coatings that can withstand abrasion are often multiphase materials sprayed through thermal spray methods, and which consist of a metal matAzmeerix, oxide particles, and void space. The maintenance of an ideal blend of qualities, such as erosion resistance and hardness, during production determines a seal’s effectiveness. The objective of this research is to develop microstructure-based modelling methodology which will mimic the coating wear process and subsequently help in designing the abradable coating composition. Microstructure modelling, meshing, and wear analysis using many tools such as Fusion360, Hyper Mesh, and LS-Dyna, have been employed to develop an abradable coating model and perform wear analysis using a simulated rub rig test. The relation between percentage composition and morphology variations of metal, oxide, and voids to the output parameters such as hardness, abradability, and other mechanical properties is explored using simulated finite analysis models of real micrographic images of abradable coatings. Full article

With the development of industry, the operating temperature of aero engines and gas turbines continues to increase; developing thermal barrier coatings (TBCs) with superior resistance to CaO-MgO-Al₂O₃-SiO₂ (CMAS) corrosion has become a prominent research focus. In this study, atmospheric plasma spraying (APS) was used to prepare yttria-stabilized zirconia (YSZ), nanostructured yttria-stabilized zirconia (n-YSZ), and Gd-Yb-Y-stabilized zirconia (GYYSZ) coatings. The effects of CMAS exposure on the microstructure, chemical composition, phase transition, and microhardness of the coatings were investigated. Comparative analysis revealed that both phase transition and exfoliation occurred in corroded YSZ and n-YSZ coatings, with n-YSZ exhibiting more pronounced changes. In contrast, GYYSZ coatings remained stable without phase transition and exhibited a smaller increase in microhardness (270 HV0.3). Consequently, doping Gd/Yb/Y elements into ZrO₂ can improve the performance of TBCs. Full article

This paper presents a special analysis study about the gas turbine operating line, and an overall description of a gas turbines project, based on experimental data from two particular applications, in order to convert two different types of aero engines into the same engine configuration. The experimental works were carried out with the aim of converting an Ivchenko AI-20K turboprop and a Rolls-Royce Viper 632-41 turbojet into free turbine turboshaft engines, to be used in marine propulsion, and also to obtain an experimental database to be used in other gas turbine applications. In order to carry out the experimental work, the engines were tested in turbojet configuration, to simulate the free turbine load by using jet nozzles with different geometries of the outlet cross-section. Following the engines’ tests, a series of measured data were obtained, through which it was possible to experimentally determine the operating line of some engine components such as the compressor, turbine, and exhaust jet nozzle. This paper is comprehensive and useful through its scientific and technical guidelines, the operation curves coming in handy in the thermodynamic analysis and testing methodology for researchers dealing with similar applications. Full article