Document
N89-12877
TURBINE ENGINE HOT SECTION TECHNOLOGY (HOST) PROJECT Daniel E. Sokolowski and C. Robert Ensign NASA Lewis Research Center Cleveland, Ohio The Hot Section Technology (HOST) Project is a NASA-sponsored endeavor to improve the durability of advanced gas-turbine engines for commercial and military aircraft. Through improvements in analytical models and life-prediction systems, designs for future turbine-engine hot section components - the combustor and turbine - will be analyzed more accurately and, thus, will incorporate features required for longer life in the more hostile operating environment of high performance engines.
Started in fiscal year 1981, the HOST Project has activities currently planned through 1989 with an estimated total cost of over $44 million. While the Project's focused research activities are necessarily analytical in nature, significant experimental testing is required for better understanding of problems as well as model verifications. The efforts are being conducted in-house at the NASA Lewis Research Center, under contracts with major domestic turbine-engine manufacturers and under grants to qualified universities. The contract and grant total funding is approximately one-half of the total budget for fiscal year 1987.
At NASA Lewis the HOST Project serves as the focal point for advocacy, funding, technical coordination, and information exchange. This workshop serves as the primary vehicle for this last function; that is, to disseminate information and elicit the exchange of ideas among participants.
Activities of the HOST Project are categorized under six disciplines: (I) instrumentation, (2) combustion, (3) turbine heat transfer, (4) structural analysis, (5) fatigue and fracture, and (6) surface protection. Management of the project uses the matrix approach, as shown in figure I. A subproject manager is responsible for each discipline and reports to the manager of the HOST Project All technical activities initiated and supported by the HOST Project are listed in table I. To surmnarize these activities and their objectives, instrumentation is being developed to obtain high-temperature, benchmark-quality data to develop and verify analysis methods. These include flow sensors (LDV), heat flux sensors (thin film), strain sensors (1800 °F static thin film), a high-frequency-response gas temperature sensor (frequency compensated), and a hot-section optical viewing system. Combustion work includes aerothermal model assessment and development as well as dilution jet modeling. In turbine heat transfer two- and three-dimensional flow and heat transfer are being studied on airfoil external boundaries, emphasizing boundary-layer transition and viscous modeling. Also being investigated is coolant-passage heat transfer, including midchord jet impingement cooling and rotational passage effects. Structural analysis includes research into thermal mechanical load models, component geometry-specific models, three-dimensional inelastic analysis methods development, development of a thermal structural cyclic test facility, and constitutive model development for both isotropic and anisotropic
materials in single-crystal and directionally solidified forms. Fatigue and
fracture includes research in life-prediction methods for creep-fatigue interactions
and elastoplastic crack propagation. Surface protection research includes studies
of corrosion phenomena, and thermal barrier coating analysis method developments.
To further understand the organization of the project and, more importantly,
the reasons for its activities, it is useful to consider the critical steps leading
to life prediction. The flow diagram in figure 2 shows such critical steps and may
be used for any hot section subcomponent; for example, combustor liners, turbine
blades, or turbine vanes. The first series of steps in figure 2 defines the engine
subcomponent geometry, material, and operating requirements. The remaining steps
are those being addressed by the HOST Project: (1) characterizing the hot section
environment, (2) characterizing thermomechanical loads, (3) determining material
behavior and structural response due to imposed loads, and (4) predicting life for
subcomponents exposed to cyclic operation. For these steps the technology needs and
notable technical progress to date are shown in figures 3 to 6.
Workshop publications and many contractor final reports carry the label "For
Early Domestic Dissemination" (FEDD) to protect national interests and, thus, are
available only to qualified U.S. citlzens. Although contractor final reports have
been published, they often represent initial phases of multiphased work. Thus, this
annual workshop report is the primary document for reporting technical results for
the entire project.
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TABLE I. - HOST Project Act|vtttes Contract (C), Grant (G), o¢ mASAOr_ntzation (N) Number Instrumentation _$3-_I_ Hot Section Viewing System ........................... C Dynam!c Gas Temperature Reasurement Systlm - A ................. C ;¢_S3-24228 Dynamic Gas Temperature P_asurement System - B ................. C l¢_S3-23 lrR Turbine Static Strain Gage - A ............ _ ............ C W_S3-23122 Turbine Static Strain Gage - B ......................... C W, S3-23S2g TurbineHeat F|ux Sensors ........................... C K_S3-26615 Laser Speckle Strain Measurement ........................ C mQ_3-SOl Hot Section Sensors .............................. N 2510 2520/253O Laser Anemametry forHot Section Applications ................. H HOST Instrument Applications .......................... M Combustion I¢_S3-23523 Assessment of Combustor Aerotherma! Models - I ................. C NAS3-23524 Assessnent of Combustor Aerothermai ttodels - I! ................ C W_S3-2",JS2S Assessment of Combustor Aerothermal Rodels -III ................ C W_S3-24351 Improved Numerical Methods - I ......................... C NAS3-24350 Improved Numerical Methods - II ........................ C WC_S96 Improved Numerical Methods -IIl ........................ G Flow Interaction Experiment .......................... C l_3-.24350 NAS3-243S0 Fuel Swirl Characterization - I ........................ C NAS3-24352 Fuel Swirl Characterization - II ................... ..... C Rass and Romenta Transfer ........................... C ;MS3-22;71 Oiffuser/combustor Interaction ......................... C F33615-84-C-..2427 NAS3-2?. 110 Otlution Jet Hixin_ Studies .......................... C Lateral Jet Injection into Typical Combustor Flowfields ............ G WG3-S4g Flame Radiation Studies ............................ M 2650 Turbine Heat Transfer Rainstream Turbulence Influence on Flow in Turning Duct - A ......... C B_S3-,?.3278 Rainstream Turbulence Influence on Flow in : Duct B G NAG3,-617 Turning .........
NAS3-..22761 2-OHeat Transfer without Film C_lin_ ..................... C 2-0 Heat Transfer with leading Edge Film _llng ................ C W_3-.23695 NA53-.246 lg 2-0 Heat Transfer with Downstream Film Cooling ................. C Reasure_nt of Blade and Vane Heat Transfer Coefficient in a Turbine Rotor" . . . C Wk53-23111 _MS3._/I6 Assessment of 3-OBoundary Layer Code ..................... C Coolant Side Heat Transfer with Rotation .................... C NAS3..236g I NAS3-?.4358 Analytic Flow and Heat Transfer ........................ C Effects of Turbulence on Heat Transfer ..................... G WW_1-$22 NAG3-623 Tip Region Heat Transfer ............................ G NSG3-O;S _pingement Coollng .............................. Q IMG3-stg Computation of Turbine Blade Heat Transfer ................... G 264O Advanced Instrumentation _ve1_nt N 262O Warm Turbine Flow Rapping with Laser A_etry " _ _ i _ i i _ _ _ _ _ i i _ _ _ N Real Engine-Type Turbine Aerothemal Testing .................. N Structural Analysis NAS3-23272 Thermal/Structural Load Transfer Code ..................... C NAS3-23697 3-0 Inelastic Analysis Methods - I ....................... C 1_3-,?.3698 3-0 Ine|astic Analysis Methods - II ...................... C NAS3-23681 Continent Specific Modeling .......................... C Liner Cyclic Life Determination ........................ N $210 Structural ConTinents Response Progrtun ..................... N High Temperature Structures Research Laboratory ................ N $210 Constitutive Model Development ......................... N NAS3-2392S Constitutive Modeling for Isotropic Raterials - Z ............... C NAS3.-?.392 ) Constitutive Modeling for lsotropic Ratertals ZI ............... C NAG3-511 W_63-$12 8iaxial Constitutive Equation Develc_nt for Single C_ta1$ and Ot_ti_lly G Solidified Alloys ..............................
Fatigue and Fracture W_$3-23298 CrY=p-Fatigue Life Prediction for Isotrooic Materials ............. C NAS3-23940 Elevated Temperature Crack Propagation ......... . ............ C NA53-23939 Life Prediction and Material Constitutive Behavior for Anir_t_Ic Materials . . C N_1-348 Ar_lysis of Fatigue Crack Growth 14echanism Vitalization of High Temperature Fatigue and'Str_cture; 6al_o;atory" : : : : : : : "G $220 Surface Protection Effects of Surface Chemistry on Hot Corrosion ................. C NAS3-23926 _S3.-,?.3943 Thernkll Barrier Coating Life Prediction - I .................. C Thermal Barrier Coating Life Prediction - U .................. C W_$3-23944 t_$3.-2394,S Thermal Barrier Coating Life Prediction - II! ................. C NAG3-201 Airfoil Deposition Rode1 ............................ a HCC3-21 Mechanical Behavior of There1 Barrier Coatings ................ G Coating Oxidation/Diffusion Prediction ..................... N Oeposition I_del Verification ......................... H SI60 Dual Cycle Attack ............................... N Rig/Engine Correlation ............................. # Burner Rig Modernization ............................ N 5160 Notes: A, B Activities in series I, II, IIl Activities in parallel.
ORGANIZATION: HOT SECTION TECHNOLOGY (HOST) PROJECT
AEROSPACE AERONAUTICS TECHNOLOGY DIRECTORATE D IRECTORATE HOST PROJECT OFFICE D. E. SOKOLOWSKI MANAGER INSTRUMENTATION -- AND CONTROL I_-
D. R. ENGLUND, JR. '_ I INSTRUMENTATION I
TECHNOLOGY OFFICE I
COMBUSTION R. E. GAUGLER_ MECHANICS
I_ t INTERNAL FLUID ___
TURBINE HEAT TRANSFER DIVISION H. J. GLADDEN" STRUCTURAL ANALYSIS R. L. THOMPSON _' (' SUBPROjECT MANAGER DIVISION STRUCTURES I-- FATIGUE AND FRACTURE G. R. HALFORD_ SURFACE PROTECTION MATERIALS R. A. MILLER '_ DIVISION CS-B5-3358 Figure 1
FRAMEWORK FOR THE HOST PROJECT
INTEGRATION OF ANALYSES
AND MATERIALS
_EADS TO LIFE PREDICTION • COMBUSTOR LINERS
GEOMETRY DEFINITION • TURBINE BLADES • TURBINE VANES MISSION DEFINITION I AIRCRAFT I ENGINE I OPERATING • I REQUIRE- • CONSTITUTIVE FAILURE
i
MODELS CRITERIA MECHANfCAL LOCAL ENVIRONMENT LOADS STRUCTURAL CHARACTER- PREDICTION CHARACTER- RESPONSE DAMAGE I HOT SECTION y SUMMATION
TH--Oy
L'FE I
IZATION IZATION Figure 2
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HOT SECTION ENVIRONMENT
NEE.._.D.D • TO BETTER UNDERSTAND AND PREDICT THE AEROTHERMAL ENVIRONMENT AROUND HOT SECTION PARTS.
HOST PROGRESS • DEVELOPED VIEWING SYSTEM AND TESTED IN PW 2037 AND HPF; FUEL INJECTOR OPERATION, LINER HOT SPOTS, AND LINERNANE CRACKING CAN BE OBSERVED.
• DEVELOPED DYNAMIC GAS TEMPERATURE MEASUREMENT SYSTEM AND TESTED IN F-100 AND HPF; GAS TEMPERATURE FLUCTUATIONS CAN BE ACCURATELY DETERMINED UP TO 1-KHz AND 3000 °F PEAKS.
• EVOLVED LASER ANEMOMETRY FOR MEASUREMENTS IN COMBUSTOR EX- HAUST STREAM; EFFORTS UNDERWAY FOR MEASUREMENTS WITHIN TURBINE.
• IMPROVING RESOLUTION OF SPATIAL PROPERTY VARIATIONS AND QUANTI- TATIVE ACCURACY OF AEROTHERMAL CODES, THROUGH 3-D NUMERICAL SCHEMES, IMPROVED TURBULENCE AND CHEMISTRY MODELS, AND RELEVENT BENCHMARK DATA.
• OBTAINED BROAD DATA BASE AND DEVELOPED EMPIRICAL MODEL FOR MIXING DILUTION AIR JETS WITH COMBUSTION GASES; COMBUSTOR EXIT TEMPERATURES PREDICTED ACCURATELY WITHIN RANGE OF DATA BASE; 3-D NUMERICAL CODES BEING IMPROVED IN SPEED AND GEOMETRIC CAPABILITIES.
Figure 3
THERMOMECHANICAL LOADS
NEED • TO BETTER UNDERSTAND AND PREDICT THE THERMAL AND MECHANICAL LOADS ON CRITICAL PARTS LIKE LINERS, BLADES, AND VANES.
HOST PROGRESS • EVOLVED TOTAL HEAT FLUX SENSORS FROM LINERS TO AIRFOILS; SENSITIVITY TO HEAT FLUX GRADIENTS ALONG AIRFOIL MUST BE MINIMIZED.
• DETERMINED THE EFFECTS OF ROTATION ON COOLANT HEAT TRANSFER IN SMOOTH-WALL PASSAGES AND MODIFIED "TEACH" CODE; SIMILAR EFFORTS UNDERWAY FOR TURBULATED PASSAGES.
• DETERMINATION OF ROTATION ON AIRFOIL HEAT TRANSFER STARTING TO PRODUCE RESULTS.
• ASSESSED 3-D BOUNDARY LAYER CODE; AGREEMENT WITH DATA IS GENERALLY GOOD.
• OBTAINED BROAD DATA BASES AND MODIFIED STAN5 CODE TO ACCURATELY PREDICT HEAT TRANSFER COEFFICIENTS, ESPECIALLY AT THE TRANSITION POINT, FOR FILM AND NON-FILM COOLED AIRFOILS.
Figure 4
STRUCTURAL RESPONSE
NEED • TO IMPROVE PREDICTION ACCURACY AND EFFICIENCY OF STRESSES AND STRAINS ON HOT SECTION METALLIC PARTS DUE TO THERMOMECHANICAL LOADS.
HOST PROGRESS • DEVELOPED STRAIN MEASUREMENT APPROACH HAVING 1300 OF CAPABILITY; EFFORTS UNDERWAY TOWARD 1800 °F CAPABILITY.
• DEVELOPED INTERFACING CODE WHICH AUTOMATICALLY TRANSFERS 3-D THERMAL INFORMATION FROM A HEAT TRANSFER CODE (COARSE GRID) TO A STRUCTURAL ANALYSIS CODE (FINER GRID).
• DEVELOPED 3-D INELASTIC STRUCTURAL ANALYSIS CODES FOR NONLINEAR BEHAVIOR AT HIGH THERMOMECHANICAL LOADS; THREE CODES COVER DIFFERENT APPROACHES--MOMM, MHOST, BEST3D; PROVIDED TENFOLD INCREASE IN COMPUTATIONAL EFFICIENCY WITH IMPROVED ACCURACY.
• DEVELOPED SEVERAL VISCOPLASTIC CONSTITUTIVE MODELS FOR BOTH ISOTROPIC AND ANISOTROPIC MATERIALS; BROADENED DATA BASE; VERIFIED MODELS FOR RANGE OF TEST CONDITIONS; HIGH TEMPERATURE STRESS/ STRAIN PREDICTION CAPABILITY IMPROVED BY 30-PERCENT; LEWIS IS INTER- NATIONALLY RECOGNIZED LEADER IN CONSTITUTIVE MODEL DEVELOPMENT.
• DEVELOPED MODULAR CODE FOR NONLINEAR STRUCTURAL ANALYSES OF LINERS, BLADES, AND VANES OVER MISSION CYCLE; AUTOMATIC SOLUTION STRATEGY FOR LINERS--SIMILAR STRATEGY UNDERWAY FOR BLADES AND VANES.
Figure 5
LIFE PREDICTION
NEED • TO ACCURATELY PREDICT THE NUMBER OF CYCLES TO FATIGUE CRACK INITIATION (LIFE) AND CRACK GROWTH FOR COMPONENTS MADE OF ISO- TROPIC AND ANISOTROPIC MATERIALS THAT ARE SUBJECTED TO COMPLEX CYCLIC MECHANICAL AND THERMAL LOADS AT HIGH TEMPERATURES.
• TO ACCURATELY PREDICT THE LIFE OF THERMAL BARRIER COATINGS ON LINERS AND AIRFOILS.
HOST PROGRESS • DEVELOP NEW CONSTITUTIVE EQUATIONS AND LIFE MODELS THAT CAN BE USED TO PREDICT LIFE FOR ADVANCED CONFIGURATIONS AND MATERIALS UNDER COMPLEX LOADING CONDITIONS.
• EXTENDED MODELING CAPABILITIES TO INCLUDE MULTIAXlAL (2-D AND 3-D) STRESS STATES AND THERMOMECHANICAL LOADING CONDITIONS • EXTENDED LABORATORY TESTING CAPABILITIES TO PERMIT COMPLEX THERMO- MECHANICAL TESTS NEVER BEFORE POSSIBLE.
• SOME PREDICTIONS HAVE SHOWN IMPROVEMENTS IN ACCURACY BY A FACTOR OF TWO.
• SIGNIFICANT PROGRESS TOWARD DEVELOPING LIFE PREDICTION MODELS FOR BLADES MADE WITH ANISOTHOPIC MATERIALS, • FORMULATED OXIDATION/THERMAL STRAIN MODEL FOR TBC LIFE PREDICTION (LeRC) THAT IS BASIS FOR TWO PRELIMINARY LIFE PREDICTION MODELS DEVELOPED BY P&W AND GTEC.
Figure 6