As-Built Geometry and Surface Finish Effects on Fatigue and Tensile Properties of Laser Fused Titanium 6Al-4V

The as-built material behavior of additive manufactured (AM) Titanium (Ti) 6Al-4V is investigated in this study. A solution heat treated, aged, stress relieved, and hot isostatic pressed Laser Powder Bed Fusion (LPBF) AM process was used to manufacture the specimens of interest. The motivation behind this work is based on the ever-growing desire of aerospace system designers to use AM to fabricate components with novel geometries. Specifically, there is keen interest in AM components with complex internal cooling configurations such as turbine blades, nozzle vanes, and heat exchangers that can improve small scale propulsion performance. Though it is feasible to three-dimensionally print parts that meet the Fit portion of a part characteristic description and identification, the Form and Function portions have proven to be more difficult to conquer. This study addresses both the Form and Function characteristics of the LPBF AM process via the investigation of geometry variation and surface roughness effects pertaining to mechanical properties and fatigue behavior of Ti 6Al-4V. Results show that geometry variation may be the cause of increased vibration fatigue life uncertainty. Also, both fatigue and tensile properties show profound discrepancies associated with surface finish. As-built surface finish specimens have lower fatigue and ductility performance, but the results are more consistent than polished data.

Measuring Water Film Thickness in a Wet Gas Compressor Diffuser: Design, Calibration, and Testing of Electromagnetic Probes

The distribution of water in the diffuser of a wet gas compressor is not well understood. Measurements of water film thickness across the diffuser surface would improve the understanding of two-phase flow phenomena in wet gas compressors. Electromagnetic probes were designed in order to measure water film thickness in the diffuser of a SwRI-designed wet gas compressor. The probes consisted of two electrode foils plated on a thin insulating substrate, allowing them to be bonded in place without drilling through the diffuser. An AC signal was passed between the electrodes, and the voltage across a resistor in series with the electrodes was recorded. As the water level covering the electrodes increased, the recorded voltage increased. A method of calibrating the probes was developed and used prior to installation in the diffuser. Testing showed the probes to be effective at detecting the presence of water in the diffuser and indicating the general water level. Improvements in probe design, calibration, and installation are needed to provide more precise water film thickness data.

A Fault Diagnosis Approach for Rolling Element Bearing Based on S-Transform and Artificial Neural Network

The condition monitoring and fault diagnosis of rolling element bearing is a very important research content in the field of gas turbine health management. In this paper, a hybrid fault diagnosis approach combining S-transform with artificial neural network (ANN) is developed to achieve the accurate feature extraction and effective fault diagnosis of rolling element bearing health status. Considering the nonlinear and non-stationary vibration characteristics of rolling element bearing under stable loading and rotational speeds, S-transform and singular value decomposition (SVD) theory are firstly used to process the vibration signal and extract its time-frequency information features. Then, radical basis function (RBF) neural network classification model is designed to carry out the state pattern recognition and fault diagnosis. As a practical application, the experimental data of rolling element bearing including four health status are analyzed to evaluate the performance of the proposed approach. The results demonstrate that the present hybrid fault diagnosis approach is very effective to extract the fault features and diagnose the fault pattern of rolling element bearing under different rotor speed, which may be a potential technology to enhance the condition monitoring of rotating equipment. Besides, the advantages of the developed approach are also confirmed by the comparisons with the other two approaches, i.e. the Wigner-Ville (WV) distribution and RBF neural network based method as well as the S-transform and Elman neural network based one.

A Physics-Based Dynamic Model for Boilers: Part 2 — Model Reduction in a Cogeneration Application

This paper is the second part of a two part study that develops, validates and integrates a one-dimensional, physics-based, dynamic boiler model. Part 1 of this study [1] extended and validated a particular modelling framework to boilers. This paper uses this framework to first present a higher order model of a gas turbine based cogeneration plant. The significant dynamics of the cogeneration system are then identified, corresponding to states in the gas path, the steam path, the gas turbine shaft, gas turbine wall temperatures and boiler wall temperatures. A model reduction process based on time scale separation and singular perturbation theory is then demonstrated. Three candidate reduced order models are identified using this model reduction process, and the simplest, acceptable dynamic model of this integrated plant is found to require retention of both the gas turbine and boiler wall temperature dynamics. Subsequent analysis of computation times for the original physics-based one-dimensional model and the candidate, reduced order models demonstrates that significantly faster than real time simulation is possible in all cases. Furthermore, with systematic replacement of the algebraic states with feedforward maps in the reduced order models, further computational savings of up to one order of magnitude can be achieved. This combination of model fidelity and computational tractability suggest suggests that the resulting reduced order models may be suitable for use in model based control of cogeneration plants.

Study of Interlaminar Fracture Properties of Ceramic Matrix Composites at Room and Elevated Temperatures

Interlaminar fracture properties play an important role in predicting failure of structural components for CMC materials. In engine applications, components are subject to large thermal gradients which induce interlaminar stresses. One of the main challenges in evaluating interlaminar fracture toughness at room and elevated temperatures is the development of an experimental setup that provides ease for testing and allows for in-situ monitoring of the interlaminar crack growth. Therefore, a wedge-loaded DCB testing method is developed. The method utilize electrical resistance to monitor crack growth and was applied to a woven polymer infiltrated pyrolysis (PIP) SiC/SiNC composite. Post-testing inspection was carried out using optical microscopy of polished cross-sections, showing crack morphology. It was found that crack growth rate at room temperature is double the one at 815 °C for initial tests in this composite system. Estimates of Mode I energy release rate suggests flat R-curve behavior at room temperature in comparison to rising R-curve behavior at 815 °C.

Exploring GasTurb 12 for Supplementary Use on an Introductory Propulsion Design Project

The purpose of this paper is to explore GasTurb 12, a commercial gas turbine engine performance simulation program, for supplementary use on an introductory propulsion design project in an undergraduate course. This paper will describe several possible opportunities for supplementing AEDsys (Aircraft Engine Design System Analysis) version 4.012, the engine design software tool currently in use. The project is assigned to juniors taking their first propulsion course in the aeronautical engineering major at the USAF Academy. This course, Aeronautical Engineering 361, which focuses on cycle analysis and selection, is required of all aero majors and is used to satisfy the ABET Program Criterion requiring knowledge of propulsion fundamentals. This paper describes the most recent design project that required the students to re-engine the USAF T-38 with the aim of competing for the Advanced Pilot Training Program (T-X) program. The goal of the T-X program is to replace the T-38 aircraft that entered service in 1961 with an aircraft capable of sustained high-G operations that is also more fuel efficient. The design project required the students to select an engine-cycle for a single, non-afterburning, mixed stream, low bypass turbofan engine to replace the two J85 turbojets currently in the T-38. It was anticipated that the high specific thrust requirements might possibly be met through the use of modern component measures of merit to include a much higher turbine inlet temperature. Additionally, it was anticipated that the required 10% reduction in thrust specific fuel consumption might possibly be achieved by using a turbofan engine cycle with a higher overall pressure ratio. This paper will describe the use of GasTurb 12 to perform the same design analysis that was described above using AEDsys as well as additional features such as numerical optimization, temperature-entropy diagrams, and the generation of scaled, two-dimensional engine geometry drawings. The paper will illustrate how GasTurb 12 offers important supplementary information that will deepen student understanding of engine cycle design and analysis.

A Thermodynamic Transient Model for Performance Analysis of a Twin Shaft Industrial Gas Turbine

In this study, a Simulink model based on fundamental thermodynamic principles to predict the dynamic and steady state performance in a twin shaft Industrial Gas Turbine (IGT) has been developed. The components comprising the IGT have been implemented in the modelling architecture using a thermodynamic commercial toolbox (Thermolib, EUtech Scientific Engineering GmbH) and Simulink environment. Measured air pressure and air temperature discharged by compressor allowed the validation of the modelling architecture. The model assisted the development of a computational tool based on Artificial Neural Network (ANN) for compressor fault diagnostics in IGTs. It has been demonstrated that modelling plays an important role to predict and monitor gas turbine system performance at different operating and ambient conditions.

Multi-Stage System Identification of a Gas Turbine

Several techniques have recently been proposed to identify open-loop system models from input-output data obtained while the plant is operating under closed-loop control. So called multi-stage identification techniques are particularly useful in industrial applications where obtaining input-output information in the absence of closed-loop control is often difficult. These open-loop system models can then be employed in the design of more sophisticated closed-loop controllers. This paper introduces a methodology to identify linear open-loop models of gas turbine engines using a multi-stage identification procedure. The procedure utilizes closed-loop data to identify a closed-loop sensitivity function in the first stage and extracts the open-loop plant model in the second stage. The closed-loop data can be obtained by any sufficiently informative experiment from a plant in operation or simulation. We present simulation results here. This is the logical process to follow since using experimentation is often prohibitively expensive and unpractical. Both identification stages use standard open-loop identification techniques. We then propose a series of techniques to validate the accuracy of the identified models against first principles simulations in both the time and frequency domains. Finally, the potential to use these models for control design is discussed.

Damage Development in SiCf/SiC Composites Through Mechanical Loading

Sophisticated mechanical characterisation is vital in support of a fundamental understanding of deformation in ceramic matrix composites. On the component scale, “damage tolerant” design and lifing philosophies depend upon laboratory assessments of macro-scale specimens, incorporating typical fibre architectures and matrix under representative stress-strain states. Standard SiCf/SiC processing techniques inherently introduce porosity between the individual reinforcing fibres and between woven fibre bundles. Subsequent mechanical loading (static or cyclic) may initiate cracking from these stress concentrations in addition to fibre/matrix decohesion and delamination. The localised coalescence of such damage ultimately leads to rapid failure. Proven techniques for the monitoring of damage in structural metallics, i.e. optical microscopy, potential drop systems, acoustic emission (AE) and digital image correlation (DIC), have been adapted for the characterisation of CMC’s tested at room temperature. As processed SiCf/SiC panels were subjected to detailed X-ray computed tomography (XCT) inspection prior to specimen extraction and subsequent static and cyclic mechanical testing to verify their condition. DIC strain measurements, acoustic emission and resistance monitoring were performed and correlated to monitor the onset of damage during loading, followed by intermittent XCT inspections throughout the course of selected tests.

Inhomogeneous Strain Distribution in SiCf/SiC Coupons Under Tensile Loading

The complex structural architecture and inherent processing artefacts within ceramic matrix composites combine to induce inhomogeneous deformation and damage prior to ultimate failure. Bulk measurements of strain via extensometry or even localised strain gauging will fail to characterise such inhomogeneity when performing conventional mechanical testing on laboratory scaled coupons. The current research project has, therefore, applied digital image correlation (DIC) techniques to the room temperature axial assessment of a SiCf/SiC composite under static and ratchetted loading. As processed SiCf/SiC panels were subjected to detailed X-ray computed tomography (XCT) inspection prior to specimen extraction and subsequent mechanical testing. In situ DIC strain measurements were taken throughout the period of room temperature monotonic and ratchet style tensile tests. Contemporary acoustic emission (AE) signals were also recorded to indicate significant damage events and the onset of ultimate failure. Data from these separate monitoring techniques were correlated to indicate the sensitivity or otherwise to pre-existing artefacts within the as received CMC panels.