Analysis of uncertainties in turbine metal temperature predictions

An analysis was conducted to examine the extent to which various factors influence the accuracy of analytically predicting turbine blade metal temperatures and to determine the uncertainties in these predictions for several accuracies of the influence factors. The advanced turbofan engine gas conditions of 1700 K and 40 atmospheres were considered along with those of a highly instrumented high temperature turbine test rig and a low temperature turbine rig that simulated the engine conditions. The analysis showed that the uncertainty in analytically predicting local blade temperature was as much as 98 K, or 7.6 percent of the metal absolute temperature, with current knowledge of the influence factors. The expected reductions in uncertainties in the influence factors with additional knowledge and tests should reduce the uncertainty in predicting blade metal temperature to 28 K, or 2.1 percent of the metal absolute temperature

Thermal and flow analysis of a convection air-cooled ceramic coated porous metal concept for turbine vanes

The heat transfer and pressure drop through turbine vanes made of a sintered, porous metal coated with a thin layer of ceramic and convection cooled by spanwise flow of cooling air were analyzed. The analysis was made to determine the feasibility of using this concept for cooling very small turbines, primarily for short duration applications such as in missile engines. The analysis was made for gas conditions of approximately 10 and 40 atm and 1644 K and with turbine vanes made of felt type porous metals with relative densities from 0.2 to 0.6 and ceramic coating thicknesses of 0.076 to 0.254 mm

NASA thermal barrier coatings: Summary and update

A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The results are summarized of analytical and experimental investigations of the coatings on flat metal specimens, turbine vanes and blades, and combustor liners. Discussed are results of investigations to determine coating adherence and durability, coating thermal, strength and fatigue properties, and chemical reactions of the coating with oxides and sulfates. Also presented are the effect of the coating on aerodynamic performance of a turbine vane, measured vane and combustor liner temperatures with and without the coating, and predicted turbine metal temperatures and coolant flow reductions potentially possible with the coating. Included also are summaries of some current research related to the coating and potential applications for the coating

The NASA high pressure facility and turbine test rig

A description of the facility and turbine test rig is presented. Also discussed is the turbine cooling test program

Review and status of heat-transfer technology for internal passages of air-cooled turbine blades

Selected literature on heat-transfer and pressure losses for airflow through passages for several cooling methods generally applicable to gas turbine blades is reviewed. Some useful correlating equations are highlighted. The status of turbine-blade internal air-cooling technology for both nonrotating and rotating blades is discussed and the areas where further research is needed are indicated. The cooling methods considered include convection cooling in passages, impingement cooling at the leading edge and at the midchord, and convection cooling in passages, augmented by pin fins and the use of roughened internal walls

Potential use of ceramic coating as a thermal insulation on cooled turbine hardware

An analysis was made to determine the potential benefits of using a ceramic thermal insulation coating of calcia-stabilized zirconia on cooled engine parts. The analysis was applied to turbine vanes of a high temperature and high pressure core engine and a moderate temperature and low pressure research engine. Measurements made during engine operation showed that the coating substantially reduced vane metal wall temperatures. Evaluation of the durability of the coating on turbine vanes and blades in a furnace and engine were encouraging

Ceramic thermal-barrier coatings for cooled turbines

Coating systems consisting of a plasma sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential was analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady state operation on cooled vanes and blades at gas temperatures as high as 1644 K with 35 start and stop cycles. On the basis of durability and processing cost, the yttria stabilized zirconia was considered the best of the three coatings investigated

Comparison of predicted and experimental external heat transfer around a film cooled cylinder in crossflow

Calculations were made of the film cooling provided by rows of holes around the circumference of a cylinder in crossflow and the results were compared to experimental data. The calculations and experimental data were for conditions that simulate most of those that are typical of air cooled turbine vane leading edges. Injection was from a single and multiple rows of holes located at different angular locations from the stagnation line. The holes in the rows were angled normal to the flow direction and at a 25 degree angle to the cylinder wall. The calculations and experimental data were for several constant values of blowing ratios for all rows and for different blowing ratios for each row, representing a simulation of a common coolant plenum supply to multiple rows of holes. The calculations were made using a finite difference boundary layer code, STAN5. Contrary to initial expectations that injection would trip the boundary layer flow into the turbulent regime, the results indicated that the high free stream acceleration apparently kept the flow laminar for holes in the first 45 degrees past stagnation. The trend in Stanton number reduction due to coolant injection was predicted with generally good agreement at the lower blowing rates, but for multile rows of holes, agreement was poor beyond the first row

Industry tests of NASA ceramic thermal barrier coating

Ceramic thermal barrier coating (TBC) system was tested by industrial and governmental organizations for a variety of aeronautical, marine, and ground-based gas turbine engine applications. This TBC is a two-layer system with a bond coating of nickel-chromium-aluminum-yttrium (Ni-16Cr-6Al-0.6Y, in wt. percent) and a ceramic coating of yttria-stabilized zirconia (ZrO2-12Y2O3, in wt. percent). Seven tests evaluated the system's thermal protection and durability. Five other tests determined thermal conductivity, vibratory fatigue characteristics, and corrosion resistance of the system. The information presented includes test results and photographs of the coated parts. Recommendations are made for improving the coating procedures

Composite wall concept for high temperature turbine shrouds: Heat transfer analysis

A heat transfer analysis was made of a composite wall shroud consisting of a ceramic thermal barrier layer bonded to a porous metal layer which, in turn, is bonded to a metal base. The porous metal layer serves to mitigate the strain differences between the ceramic and the metal base. Various combinations of ceramic and porous metal layer thicknesses and of porous metal densities and thermal conductivities were investigated to determine the layer thicknesses required to maintain a limiting temperature in the porous metal layer. Analysis showed that the composite wall offered significant air cooling flow reductions compared to an all impingement air cooled, all metal shroud