Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy最新文献

{"title":"3D Printing of Ceramic Shell Molds for Precision Casting of Turbine Blades","authors":"L. Magerramova, B. Kozlov, E. Kratt","doi":"10.1115/gt2021-58796","DOIUrl":"https://doi.org/10.1115/gt2021-58796","url":null,"abstract":"\u0000 Traditionally, the technology used in the production of gas turbine blade castings characterized by a large number of technological conversions, high labor costs with a large amount of manual labor and the need to produce various types of complex and expensive equipment at different stages of production. This work aims to reduce the time and money spent on the manufacturing of ceramic shell shapes — a form suitable for the standard methods of precision casting by traditional heat-resistant nickel alloys. The proposed approached involves obtaining a shell shape with an internal core as a single, non-assembled product, without lengthy and time-consuming design and manufacturing processes involved in forming equipment for the production of castings based on smelted models. The proposed method is based on the use of 3D printing with refractory ceramic pastes.\u0000 Using both uncooled and cooled blades as examples, models of casting molds were designed, technological processes were developed, and ceramic shell molds were manufactured.\u0000 Experimental casting into a manufactured ceramic shell mold for an uncooled blade with a bandage shelf was performed and showed satisfactory results.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129828065","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Impact on Cycle Efficiency of Small Combined Heat and Power Plants From Increasing Firing Temperature Enabled by Additive Manufacturing of Turbine Blades and Vanes","authors":"S. Uysal, D. Straub, James B. Black","doi":"10.1115/gt2021-58718","DOIUrl":"https://doi.org/10.1115/gt2021-58718","url":null,"abstract":"\u0000 Using an analytical cooled gas turbine model and a steam cycle model, this study estimates the impact on combined heat and power (CHP) cycle performance from increasing the turbine firing temperature by 180°F (100°C) and improving the turbine blade cooling for a 6-MW scale gas turbine. A sensitivity analysis was performed to understand the impact of increasing the internal cooling effectiveness, thermal barrier coating performance, and blade material upgrades on gas turbine and CHP cycle efficiency. The impacts of turbine blade cooling improvements were studied for three common CHP cycle configurations identified from the literature. Various definitions for CHP cycle efficiency from the literature are used in the comparisons. The results show that a 180°F (100°C) increase in firing temperature can increase the gas turbine efficiency by 1 percentage point without improving cooling effectiveness and add 2 additional percentage points in efficiency by using advanced turbine blades with higher internal cooling efficiency. The engine upgrades evaluated in this study show potential for increasing the CHP cycle efficiency by 3 percentage points while increasing the steam generation rate by 8%.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124769193","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"GT26 2006 Turbine Stage 1 Blade Reconditioning Development and Qualification at Ansaldo Repair Centre","authors":"Elisa Mela, F. Fignino, Alessio Gabrielli, P. Guarnone, Emanuele Porro, R. Kellerer, Matthias Staempfli","doi":"10.1115/gt2021-59042","DOIUrl":"https://doi.org/10.1115/gt2021-59042","url":null,"abstract":"\u0000 The evolution of industrial gas turbines towards increased efficiency and performance requires even higher operating temperatures for the engines. In order to remain competitive in the market, OEM companies continuously need to develop maintenance programs and repair technologies able to extend the life of these components as much as possible.\u0000 The repair technology improvement is fundamental to reduce scrap rates and maintenance costs to be competitive on the market.\u0000 The Ansaldo Repair Centre answers to this market demand by providing advanced and competitive repair techniques and an increasing broad repair portfolio to its customers.\u0000 This paper describes the steps and approach to determine the repair process of GT26 LPT Blade 1 in order to allow the component to run another service interval. The base material status and the indication found after service was used as the foundation for a development of a dedicated repair sequence from stripping, to suitable heat treatments, to enhanced repair technique to recoating of the blade.\u0000 Particular attention was paid to the most damaged area, for which a particular welding procedure including an optimized filler material has been applied for the rebuilding of the tip and platform zones as well as for the restoration of the unique tip closing features.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"159 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134226643","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Recent Developments in Hot Isostatic Pressing (HIP) of Components for Turbomachinery Applications","authors":"C. Beamer","doi":"10.1115/gt2021-60113","DOIUrl":"https://doi.org/10.1115/gt2021-60113","url":null,"abstract":"\u0000 With advancements in hot isostatic pressing (HIP) systems it is now possible to also perform heat treatment by achieving the desired microstructure during the HIP cycle. This modern approach offers the freedom to consider a combined HIP and heat treatment cycle known as high pressure heat treatment (HPHT™). There are many potential benefits from this processing route such as shorter process times, cost reductions, increased quality, and improved productivity. Material benefits also exist from this processing route. This paper will cover the fundamentals of HPHT™ highlighting key technology changes enabling this approach in modern HIP equipment. Then a transition to recent studies capturing the benefits for aerospace applications leveraging HIP and the HPHT™ methodology along with future possibilities with steered cooling will be reviewed.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"402 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134443401","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Performance Testing of L-PBF Produced Honeycombs Out of IN625","authors":"Timo Heitmann, Ole Geisen, Lisa Hühn, O. Munz, A. Bardenhagen","doi":"10.1115/gt2021-58844","DOIUrl":"https://doi.org/10.1115/gt2021-58844","url":null,"abstract":"\u0000 Laser Powder Bed Fusion (L-PBF) enables the production of complex metallic parts. Processes using pulsed wave (PW) laser radiation have been proven to be well suited to build thin-walled honeycomb structures. However, the behavior of these structures under load conditions remains mostly unexplored. The objective of this paper is to characterize L-PBF produced honeycombs by investigating their rub and leakage performance. A pulse modulated process based on previous studies is optimized for productivity and used to build L-PBF test samples out of Inconel 625 (IN625). The honeycomb cell geometry is adjusted for improved printability of the overhanging walls. Repeatable L-PBF production of honeycombs with a wall thickness of about 100 μm is confirmed. Conventionally manufactured honeycomb samples out of sheet metal are tested as reference. The rub experiments cover radial incursion rates of up to 0.5 mm/s and relative velocities of up to 165 ms−1 at incursion depths (ID) between 0.5 and 2.0 mm. Lower incursion forces are observed for the L-PBF components, with a higher degree of abrasion. The leakage tests examine the mass flow rate for pressure ratios between 1.05 and 2.0 at constant gap size and constant back pressure. The L-PBF honeycomb seals show a higher mass flow rate, with the slightly larger cell size and higher surface roughness appearing to be the main influencing factors. Overall, improved rubbing behavior and 10 % higher leakage than the conventional probes demonstrate the applicability of L-PBF for honeycomb sealing systems. Future performance improvements through dedicated L-PBF designs can be expected.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132815424","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Manufacturing Technologies for Fir Tree Slots: A Technological and Economic Evaluation","authors":"L. Heidemanns, T. Seelbach, U. Küpper, Martin Seimann, T. Bergs","doi":"10.1115/gt2021-59652","DOIUrl":"https://doi.org/10.1115/gt2021-59652","url":null,"abstract":"\u0000 Fir tree slots in engine disks pose a great challenge to the production process, especially due to the use of increasingly filigree geometries. Broaching with high-speed steel (HSS) as cutting tool material has been established as the state of the art process. However, this manufacturing process obtains the disadvantages of high tool costs and long waiting times in case of geometry adaptations. Alternative manufacturing technologies, namely electrochemical machining (ECM) and wire electrical discharge machining (WEDM) offer the potential to replace broaching. Because of their removal mechanism being independent of the mechanical properties of the material, these processes are not hindered by increasingly higher thermomechanical material properties. Furthermore, the tool in WEDM is not specific to geometry, allowing fast adaptations. Nevertheless, the technology specific white layer may reduce the mechanical integrity of the engine disk. ECM in contrast has no negative impact on the rim zone of the workpiece but the tool is still specific to the slot geometry. Consequently, this paper experimentally investigates the three different manufacturing technologies in order to evaluate their capability to manufacture fir tree slots with respect to geometric accuracy and surface integrity. Subsequently, the technology specific manufacturing costs are considered to outline the economic potential of each process while taking into account the influence of the batch size.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133587434","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimal Design of Renewable Hydrogen Production for Gas Turbine Test Facilities","authors":"M. A. Ancona, M. Bianchi, L. Branchini, A. D. Pascale, F. Ferrari, F. Melino, A. Peretto","doi":"10.1115/gt2021-59218","DOIUrl":"https://doi.org/10.1115/gt2021-59218","url":null,"abstract":"\u0000 The growing attention to environmental issues has led to an increase in renewable source exploitation. These resources, in addition to their characteristic of zero emissions, can be employed where there is no connection to the electricity grid or to produce synthetic fuels (e.g. hydrogen or synthetic natural gas) via power-to-gas technologies.\u0000 In the context of the ERA-Net Project ZEHTC (Zero Emission Hydrogen Turbine Center), the aim of this paper is the development of a design calculation model for the ZEHTC pilot plant, consisting in the first gas turbine test facility making use of the power produced during tests — along with renewables — for hydrogen production, integrated with batteries. The hydrogen is locally used — mixed with natural gas — to run the gas turbine, reducing its environmental impact.\u0000 The developed code aims at maximizing the conversion of the renewable source into hydrogen and guaranteeing its availability for the planned tests. It includes physical-mathematical models for each component and has been used to perform a parametric analysis varying the main components size, thus estimating the total produced hydrogen.\u0000 The main innovation of the ZEHTC micro-grid project consists in the use of a gas turbine — instead of a fuel cell — as system to reconvert the stored hydrogen.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131023694","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of the Tool Wear on the Quality and Service Life of Gears for the Geared Turbofan Technology Machined by Five-Axis Milling","authors":"T. Lakner, Christoph Zachert, R. Greschert, D. Schraknepper, T. Bergs","doi":"10.1115/gt2021-59172","DOIUrl":"https://doi.org/10.1115/gt2021-59172","url":null,"abstract":"\u0000 The geared turbofan technology is one essential way to reduce the fuel consumption, the environmental footprint and the noise pollution of civil aircrafts. An added gearbox between the fan and the low-pressure compressor that reduces the fan speed, which allows higher bypass ratios, achieves the mentioned benefits of geared turbofans. To withstand the high mechanical loads, large double helical gears are used. Gear hobbing and gear grinding require large tool maneuvering spaces. This leads to a larger required space between the single gears of the double helical gear. As a result, the gears are larger and heavier, which leads to a reduced economy of the aircraft. The tool maneuvering space of five-axis milling with solid carbide end mills is much smaller. This enables the design of smaller, lighter and more efficient aircraft engines. However, manufacturing these gears in tolerances better than IT5 is very challenging on five-axis milling machine tools. This paper presents investigations about finish machining of hardened gears on five-axis machine tools. In the investigations performed, varying tool substrates and tool coatings have been investigated together with tool travel paths in order to reduce the tool wear, which is key to achieve the demanded tolerances. Finally, the five-axis milled gears were compared to conventionally manufactured gears on test benches to enable statements regarding the expectable service lives of the manufactured gears.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"60 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126613843","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Weldability and Properties of Newly Developed LW4280 High Gamma Prime Nickel Based Superalloy for 3D AM and Repair of Turbine Engine Components","authors":"Alexandre Gontcharov, P. Lowden, Ashutosh Jena, S. Kwon, M. Brochu","doi":"10.1115/gt2021-58851","DOIUrl":"https://doi.org/10.1115/gt2021-58851","url":null,"abstract":"\u0000 Chemical composition, structure, mechanical and oxidation properties of welds produced utilizing laser direct energy deposition process of a newly developed LW4280 welding powder will be presented. Crack-free and high-density specimens were fabricated for manufacturing standard and subsized tensile test samples as per ASTM E-8. Optical and scanning electron microscopy revealed the formation of epitaxial grain growth during solidification of the welding pool followed by precipitation of fine gamma prime phase during the reheating from the subsequent weld layers. A sub-solvus primary aging temperature determined using Thermo-Calc software followed by secondary aging resulted in precipitation of above 49% of cuboidal γ′ phase. Excellent ultimate tensile strength of 1310 MPa (190 ksi), 0.2% yield strength of 855 MPa (124 ksi), and elongation of 18.7% were measured at ambient temperature. At 926°C (1700°F), the tensile testing yielded of 579 MPa (84 ksi), 0.2% yield strength of 462 MPa (67 ksi), and elongation of 18.8%. Cyclic oxidation resistance of the LW4280 weld material at 1120°C (2048°F) was superior to Rene 80 and Mar M247 while slightly below Rene 142.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"85 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123938838","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Developing an Implicit Creep Model From Open Literature Data","authors":"W. D. Day","doi":"10.1115/gt2021-59765","DOIUrl":"https://doi.org/10.1115/gt2021-59765","url":null,"abstract":"\u0000 As pressure ratios and firing temperatures continue to rise, creep becomes of greater concern everywhere within a gas turbine engine. As a rule of thumb, just a 14°C increase in metal temperature can halve the expected rupture life of a part. In the past, companies might be satisfied with conservative creep estimates based on Larson-Miller-Parameter curves and 1D calculations. Now companies need functional implicit-creep models with finite element analysis for an ever-increasing number of materials. Obtaining adequate test data to create a good creep prediction model is an expensive and time-consuming proposition. Test costs depend on temperature, material, and location, but a single, 10,000hr, rupture test may reasonably be expected to cost > $20,000. Other than large OEMs, small companies and individuals lack the resources to create creep models from their own data. This paper will lead the reader through the creation of a modified theta projection creep model of Haynes 282, a high-temperature, combustion alloy, using only literature data. First, literature data is collected and reviewed. Data consists of very few complete curves, estimated stresses for rupture and 1% strain, and discrete times to individual strains for individual tests. When adequate data exists, individual tests are fit to theta projection model curves. These “local” theta fits of different test conditions are used as input for the global model. Global fits of theta parameters, as a function of stress and temperature, are made from the full data set. As the global creep model is improved, correction factors introduced to account for true stress and strain effects. A statistical analysis is made of actual rupture time versus predicted onset of failure time, theta5=1. A time-based scatter factor is determined to evaluate temperature margin required to ensure reliability. After the creep model was completed, Haynes International, the material inventor, provided specific test conditions (stress and temperature) of 5 tests that had already been run. Creep predictions were generated for these test conditions, before viewing the actual results. The creep model predicted strain curves matched actual tests very well, both in shape and time to rupture. Continued refinement is possible as more data is acquired.","PeriodicalId":286637,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy","volume":"356 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132965397","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}