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1 THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS 345 E. 47th St., New York, N.Y Se Society The shall not be responsible for statements or opinions advanced in papers or discussion at meetings of the Society or of its Divisions or Sections, or printed in its publications. Discussion is printed only if the paper is published 95-GT-287 m in an ASME Journal. Authorization to photocopy material for internal or personal use under circumstance not falling within the fair use provisions of the Copyright Act is granted by ASME to libraries and other users registered with the Copyright Clearance Center (CCC) Transactional Reporting Service provided that the base fee of $0.30 per page is paid directly to the CCC, 27 Congress Street, Salem MA Requests for special permission or bulk reproduction should be addressed to the ASME Technical Publishing Department. Copyright 1995 by ASME All Rights Reserved Printed in U.S.A. RESEARCH AND DEVELOPMENT STATUS OF ADVANCED MATERIAL GAS-GENERATOR (AMG) PROJECT M. Hiromatsu T. Yamamura T. Chikata T. Sekido S. Ohama H. Miyagawa I. Murakami S. Seki Research Institute of Advanced Material Gas-Generator Co.,Ltd Bunkyo-ku, Tokyo, Japan ABSTRACT Advanced Material Gas-Generator (AMG) R&D Project was initiated in 1993 as a ten year's program with a joint investment from Japan Key Technology Center and fourteen participating domestic companies. The program objective is to establish basic key technologies for next generation gas-generator using advanced materials, which should have the features of significantly low fuel consumption with reduced weight and size, and should be environmentally acceptable, toward the realization of future industrial, marine and aerospace gasturbine. The R&D themes in this project cover advanced gas-generator conceptual study, advanced material and structures, innovative system and control, and advanced components technologies such as low NOx combustor. Each R&D theme is underway toward achieving the program goal. The 1st conceptual drawing of the advanced material gas-generator is completed as the result of the conceptual study. PMC (Polymer Matrix Composites), MMC (Metal Matrix Composites), CMC (Ceramic Matrix Composites) and TiAl (Titanium- Aluminide) are considered as the candidate material for the advanced material gas-generator. This paper introduces the outline of this project, and describes the status of conceptual study and each R&D themes. joint investment from Japan Key Technology Center and fourteen companies. The company, Research Institute of Advanced Material Gas-Generator Co., Ltd., was registered in 29th March, The Aim of the project is to establish basic key technologies for next generation gas-generator featuring advanced materials. This advanced gasgenerator is expected to be applied to industrial, marine and aero-gas turbine. Advanced materials being focussed on are CMC, MMC, PMC and TiAl. Main project activity is to develop manufacturing process of advanced materials and to design and test gasgenerator components. Three major targets of technology in the R&D project are 20% improvement of specific fuel consumption (sfc), 50% reduction of weight and 70-80% reduction of NOx emission as compared with the latest gasgenerator or gas turbine as of Through this research project we expect to establish unique technology and to contribute to world-wide industry in the future. The patents and knowhows are open to the third parties with license agreements. The research period is 9 years and a month from March 1993 to March 2002 as shown in figure 1. The research fund will be a total of Y10 billion (about $100 million) of budget. CALENDAR YEAR PHASE 1 1 rreliminary TECIINOLCKV DEMONS TR A LION ) 44RClI MARCH INTRODUCTION MARCH Ph ASH II (COMPONENT I SVAil'S TE-_Ci'1 Advanced Material Gas-Generator (AMG) R&D Project was initiated with a Fig.l AMG RESEARCH & DEVELOPMENT SCHEDULE Presented at the International Gas Turbine and Aeroengine Congress and Exposition Houston, Texas - June 5-8,1995

2 The fourteen participating domestic companies are three gas turbine manufactures, five material companies, four mechanical components manufactures and two control system companies. OVERVIEW OF R&D THEMES The R&D concerning an advanced gas turbine for early 21st century is being intensively conducted in Europe and the united stats of America') -' 0 ). For such R& D of gas turbine, the important technical issues are low fuel consumption, light weight, small size and environmentally conformance. In order to achieve technical goals, realization of higher temperature and pressure in a gas turbine is required. However, usual materials such as metal have limits for use over the present condition. Therefore introduction of advanced materials centering around composite materials is indispensable for the advanced gas turbine. At the same time, it is necessary to research the design analysis technology corresponding to high speed and work of each components and innovative system/control technology which keeps optimum operating condition of each components under high temperature and pressure. we consider the above background and we have been tackling R&D themes, as shown in figure 2, in the AMG project. The R&D themes in this project cover advanced gas-generator conceptual study, advanced material and structures, innovative system and control and advanced components technologies such as low NOx combustor. CONCEPTUAL STUDY AND EACH SPECIFICATION FOR R&D THEMES In order to make clear the required specification of each R&D themes, and to confirm the feasibility of three major technical targets, the conceptual design study was conducted at the first place. Recently some of main parameters in gas turbine each components are hitting barriers. Figure 3 shows turbine inlet temperature trend. According to this trend, increase of turbine inlet temperature is going to saturate due to the maximum allowable temperature of the metal material. On the other hand, the advanced composite material have a great potential related to high temperature application. We assume that 1600 C (1873K) non-cooled turbine will be possible by using advanced composite material non-cooled turbine enables us to achieve a great improvement of fuel consumption as shown in figure 4 because compressor bleed air for turbine cooling will be not required C non-cooled turbine is supposed to be equivalent to (2273K) cooled turbine on the material point of view. 1 I t ^' ft ADVANCED SYSTEM & CONTROL Z. ACTIVE STALL C.UNTRO I. I. _ III IA LOADING TURBINE I. I..I HIGH TEMPERATURE TURBINE Fig.2 R&D THEMES IN AMG PROJECT 2

3 800 zono leoo T1. INE I I1ET T 9 FEATI 1800 I TI Lu 400 W a a ~ I METAL L COMPOSITE MATERIAL, MATERIAL Fig.3 TURBINE INLET TEMPERATURE ig.5 SPECIFIC STRENGTH VERSUS TIP SPEED IN COMPRESSOR TYPICAL CRUISE SEC SPECIFIC STRENGTH (X 10 4mi 10700m.0.8Mn,ISA L FA-i5 FAN PRESS.RAT70 OPTIMIZED [CI I- v % LOTUS? TURBINE COOLING TECHNOLOOV ADVANCED TUIN RSE COOLING TECHNOLOGY.NON000LING TURBINE H U Hg TARGET10 LOADING SU% UP ii-r,' 0' Dl OVERALL PRESSURE RATIO Fig.4 TURBINE COOLING EFFECT ON TSFC YEAR Figure 5 shows specific strength versus compressor tip speed with present metal material. And figure 6 shows temperature rise per stage in compressor. From figure 5 and 6, temperature rise per stage is about K in the current technology because the specific strength of metal materials has the limit of about 2X10 4m. If the composite materials which have the specific strength of about 4X10 4 in are applied to the compressor, temperature rise per stage can be increased by 50% in comparison with the current level for compressor temperature and specific strength. With those assumptions we carried out conceptual design of aero-engine for subsonic transport at the 1st step. Advanced Ducted Prop (ADP) engine was selected as it is thought to be a power plant in early 21st century. The engine specification is shown in table 1. Fig.6 TEMPERATURE RISE PER STAGE IN COMPRESSOR Table 1 ESTIMATED PERFORMANCE OF 21ST CENTURY'S CIVIL ENGINE THRUST THRUST Max Climb TYPE m M ISA+I Sk ( Sea Level Static ) SPECIFIC FUEL CONSUMPTION 01 kn 455kN 13.0 o,3inio TURBINE INLET TEMPERATURE 1073 K ( BYPASS RATIO 25 OVERALL PRESSURE RATIO 65 GASGENERATOR PRESSURE RATIO 21.5 Advanced Ducted Prop 3

4 As a result of the above conceptual design, it is confirmed that the great improvement (more than 20% reduction) of fuel consumption can be expected as shown in figure 7. Based on this ADP conceptual study, we then produced the 1st CRUISE SFC m,0.8Mn,ISA d E U I- 7.0 e %..0 UT6T7,J,..+FNOwF AMG TARGET 3.0 _ ^ conceptual drawing and specifications of the advanced material gas-generator, which are shown in figure 8 and table 2 respectively. As for the candidate materials, PMC, MMC, CMC and TiAl which contribute to 50% reduction in weight are applied to this gas-generator. Applied parts of these materials are mainly the followings. - Turbine Blisk (Blade + Disk) CMC - Turbine Case TIAl - Compressor Ring - Rotor MMC - Compressor Vane TiAl - Compressor Duct PMC ( 573K) - Combustion Liner CMC - Mechanical Components CMC, (Bearing, Seal, Fastener) PMC FN [kn] Fig.7 20% IMPROVEMENT OF SFC Table 2 SPECIFICATION OF AMG GAS- GENERATOR UNDER DESIGN POINT AIR FLOW (k g/s) COMPRESSOR DISCHARGE TEMPERATURE (K) TURBINE INLET TEMPERATURE (K) L URE RATIO COMPRESSOR DISCHARGE PRESSURE ( k P a) The followings are the technical targets for each component of the advanced material gas-generator. COMPRESSOR Technical targets in the compressor are as follows. - Tip Speed : 650m/s - Temperature Rise per stage : 65K - Excellent Efficiency (in the Flow Mach COMBUSTOR The present NOx discharge quantity is about 40g/kg fuel (T3=800K level) in NOx index. Figure 9 shows the target of low NOx. Fig.8 1ST CONCEPTUAL DRAWING OF ADVANCED MATERIAL GAS-GENERATOR 4

5 40r CURRENT THECHNOLOGY STATUS OF EACH R&D THEMES rn a) 0 z TURBINE TARGET LEVEL COMBUSTOR INLET TEMPERATURE [K] Fig.9 NOx INDEX IN COMBUSTOR Technical targets in the turbine are as follows. - Turbine Inlet Temperature : (non-cooled) - Efficiency : more than 91% (more than 2.0 in stage loading factor) MECHANICAL COMPONENTS Following mechanical components are also R&D objects in AMG project. - High speed/temperature ball/roll bearings - High speed/temperature seals - CMC/PMC fasteners S1 (S1 Besides the researches of the above components, control and instrument technologies are required to achieve three major targets of AMG project. The research of active stall control system aims to develop the stall control technology which expands operating range to raise pressure ratio in a compressor. The research of advanced control and accessories covers high efficiency electric motor which replaces a gear box, and composite material unit for weight reduction. The research of advanced sensors aims to develop the optical instrument and the optical correspondence technology which solves the problems of the increasing electric wire weight and of electromagnetic interference. At the time of the project go-ahead, the challenging target was set for each R&D themes aiming at the major project goals described in the preceding sections. To confirm this target, each R& D group conducted feasibility studies and then, established detailed programs as the main activities in 1993.They now initiated basic design works and preliminary testing in the level of test pieces or simplified parts. The following are the technical explanations and some topics of the R&D in each of the advanced components and controls. 1) HIGH SPEED COMPRESSOR Compressor is a key component to the high performance/high specific power gas generator. With the utilization of MMC ring rotor structure, it is considered to be possible to raise compressor tip (whirl) speed to 650m/s from the current level of 450m/s. This enables us to increase compressor work per stage by some 50%, thus reducing number of stages, which significantly contributes to the advanced gas generator in weight and size. Preliminary structural test of MMC disk was conducted, which provided important informations for design analysis and manufacturing process. On the other hand, very high work or tip speed means high flow mach number through compressor blades (up to ) in aerodynamics. Therefore, shock wave control becomes the key element to achieve high aerodynamic efficiency, and there is a growing need for 3 dimensional CFD analysis. Figure 10 shows a sample output from the design analysis work, and aerodynamic (rotational) rig test is planned in Fig.10 SAMPLE OUTPUT OF COMPUTATIONAL SIMULATION (COMPRESSOR ROTOR BLADE) 5

6 i, 2) LEAN COMBUSTOR FOR LOW NOx In the future gas generator, it is apparent that the environmental acceptability will be an key issue. Among various emissions,nox will be a major element because of the increased temperatures. In this program, with the target of 70% - 80% reduction in NOx, two types of combustors are being studied, i.e. swirl combustor and multiple fuel nozzle combustor as shown in figure 11. Fig.12 CMC TURBINE BLISK 4 ) MECHANICAL COMPONENTS MULTIPLE FUEL NOZZLE COMBUSTOR TYPE. 3Ji Fig.11 TWO TYPES OF COMBUSTOR Project goals as indicated in the preceding sections dictate vast improvements in mechanical systems such as bearings, seals and fasteners to meet the anticipated environment, rotational speed and specific features of composite materials. Initial requirements were set for each component, and design studies and preliminary rig works are being conducted in each group. Figure 13 shows one of the rig results of sample composite fastener. 3) NON - COOLING / HIGH TEMPERATURE TURBINE It is envisaged that CMC has a capability of up to 1400`C (1673K) material temperature. With this high temperature CMC, we can design noncooled turbine blade at the equivalent turbine inlet gas temperature of 1600'C (1873K) because material temperature of turbine rotor blade is estimated to be 1400t (1673K). This means, in the gas generator, a significant increase in power and thermal efficiency due to the major cut-down of parasitic flow, and also a significant weight reduction due to CMC versus metal materials. In this program, with the goal of high temperature demonstration of CMC turbine brisk (blade + disk) as shown in figure 12, material and manufacturing process development, design analysis are now underway. Initial hot spin test of CMC brisk is planned in (a) PMC BOLTS (b) CMC BOLT Fig.13 COMPOSITE FASTENERS AFTER PRELIMINARY RIG TEST 6

7 5 ) ADVANCED CONTROLS Controls and accessaries are the technology area which should contribute to the major project goals in terms of weight reduction and intelligent system control with the improved reliability in the expanded environment. Following three researches are underway in this program, - Active stall control in compressor - Integrated fuel control and pump (electric) with composite material - Optical sensors and advanced transducers Initial system studies were completed and key elements of each research are being addressed by the detailed analysis or initial model manufacturing. CONCLUDING REMARKS The project overview and its current status were presented, and particularly, the 1st conceptual design was discussed in detail to meet the three major targets of this project. The first milestone of the project is to evaluate and demonstrate of capability of technologies and materials by mid of 1997, when the fundamental component testings are scheduled to be completed. After the fundamental evaluation will be confirmed, the each component demonstration will be conducted, in which the actual gas-generator components will be tested to evaluate and confirm the component characteristics for the future application. The basic key technologies established in this project will be able to be applied to an extensive field such as an industrial gas-turbine, marine gasturbine, and aero-engine. And, particularly, the technologies related to the advanced material and mechanical components will also be applicable to another commercial field such as an energy industry, material industry, etc. It is a policy of project that the technologies established are open to the third parties with the license agreements, so that the international contribution on the technical field will be anticipated. Further project progress and experimental results will be presented in the near future. REFERENCE 1) Hill, R.J., 1993, + The Challenge of IHPTET", ISABE ) Kirk, G.E. 1989, COMPOSITE MATERIALS FOR FUTURE AERO ENGINES",ASME- 89-GT ) Sephens, J., 1990, ' NASA'S HITEMP PROGRAM FOR UHBR ENGINES", AIAA ) Smith, C.J., 1990, THE PROMISE OF ADVANCED MATERIALS FOR A 21ST CENTURY USE, AIAA ) Owens, R.E., et al, 1990, Ultra High Bypass Turbofan Technologies for the Twenty-First Century", AIAA ) Simoneau, R.J., et al, 1989, CFD IN THE CONTEXT OF IHPTET - The Integrated High Performance Turbine Technology Program", AIAA ) Tacina, R.R., 1990, COMBUSTOR TECHNOLOGY FOR FUTURE AIRCRAFT", AIAA ) Bozzola, R., 1991, ' Advanced High Work Turbine Technology", AIAA ) Pezzella, G., et al, 1990, High Temperature Liquid Lubricant Requirements For Advanced High Performance Gas Turbine Engines" AIAA ) Overstreet, M., et al, 1990, Lightweight Fuel Pump and Metering Component for Advanced Gas Turbine Engine Control", AIAA