Preparation and property of seal coating for gas turbine compressor

Double-layer structure of seal coating which consisted of a Ni5Al bond coating and a Ni25 graphite top coating were prepared on steel substrate of gas turbine compressor cylinder block.Bond coating was prepared by atmospheric plasma spraying and top coating was prepared by flame spraying.The microstructure,mechanical properties and abradability of the coating were characterized by scanning elec-tron microscope(SEM),hardness tester,universal testing machine,thermal shock testing machine and abradability testing machine.The res-ults show that the overall spraying structure of the seal coating is uniform,the nickel metal phase is the skeleton supporting the entire coat-ing,and the coating is well bonded without separation.The seal coating has a bonding strength of not less than 7.7 MPa,excellent thermal stability,and thermal shock resistance cycle numbers at 500℃more than 50;the scratch length,deepest invasion depth and wear amount of the coating increase with rise of test temperature,with almost no coating adhesion,indicating that the seal coating has excellent abradability.

Hybrid URANS/LES Method of Flow Fields in Axial-flow Compressor Rotor Rotor

Accurate and efficient prediction of the aerodynamic performance and flow details of axial-flow com-pressors is of great engineering application value for the aerodynamic design and flow control of axial-flow compres-sors.In this work,a delayed detached eddy simulation method is developed and applied to numerically simulate the tur-bulent channel flow and the aerodynamic performance of NASA Rotor 35.Several acceleration techniques including parallel implementation are also used to speed up the iteration convergence.The mean velocity distribution and Reyn-olds stress distribution in the boundary layer of turbulent channel flow and the aerodynamic performance curve of NASA Rotor 35 are predicted.The good agreement between the present delayed detached eddy simulation results and the available direct numerical simulation results or experimental data confirms the effectiveness of the developed meth-od in the accurate and efficient prediction of complex flow in turbomachinery.

Aerodynamic Design and Analysis of a Low-reaction Axial Compressor Stage

There is introduced a new low-reaction, highly-loaded axial compressor design concept which is coupled with boundary layer suction method. The characteristic features of the concept are made clear through its comparison with the MIT boundary layer suction compressor. Also are pointed out the potential applications of this concept as well as its key technological problems. Based on this concept, a single-stage, low-reaction and low-speed axial compressor is constructed in association with analysis and computation of boundary layer suction on vanes with the aid of a three-dimensional numerical approach. The results attest to the effectiveness of this way to control separation in blade cascades by the boundary layer suction and the feasibility of this proposed design concept.

Flow Field Improvement by Bowed Stator Stages in a Compressor with Different Axial Gaps Under Near Stall Condition

The outlet flow fields of a low-speed repeating-stage compressor with bowed stator stages are measured with five-hole probe under the near stall condition when the rotor/stator axial gap varies. The performances of the straight stator stages are investigated and compared to those of the bowed stator stages. The results show that using bowed stator stages could alleviate the flow separation at both upper and low corners of the suction surface and the endwalls, and decrease the losses along the flow passage as well as the outlet flow angle. As the rotor/stator axial gap decreases, although the diffusion capacity of the compressor increases obviously, the outlet flow field in the straight stator stages deteriorates quickly. By contrast, little changes occur in the bowed stator stages, indicating that as the rotor/stator axial gap decreases, improved performance is achieved in the bowed stator stages.

Numerical Investigation of the Unsteady Flow in a Transonic Compressor with Curved Rotors

The unsteady 3D flow fields in a single-stage transonic compressor under designed conditions are simulated numerically to investigate the effects of the curved rotors on the stage performance and the aerodynamic interaction between the blade rows. The results show that, compared to the compressor with unurved rotors, the compressor under scrutiny acquires remarkable increases in efficiency with significantly reduced amplitudes of the time-dependent fluctuation. The amplitude of the pressure fluctuation around the stator leading edge decreases at both endwalls, but increases at the mid-span in the curved rotors. The pressure fluctuation near the stator leading edge, therefore, becomes more uniform in the radial direction of this compressor. Except for the leading edge area, the pressure fluctuatinn amplitude declines remarkably in the tip region of stator surface downstream of the curved rotor, but hardly changes in the middle and at the hub.

NUMERICAL RESEARCH ON IMPACT OF AIR SYSTEM BLEEDING ON COMPRESSOR PERFORMANCE

Bled air from the high pressure compressor takes up 3%—5% in the air system.However,there are not many studies on the compressor performance after bleeding.By analyzing the low-speed single-stage compressors,six bleeding structures are presented according to their influence mechanism on the compressor performance,and five kinds of bleeding rate are applied to one of the structures.A numerical simulation is performed to study the influence of bleeding rates and structures on the compressor performance.The results show that for the stators with the large flow separation in the corner,bleeding a small amount of air from the end-wall region can improve the total pressure increase and the stability margin.Moreover there is an optimum value of the bleeding rate in the stator casing.

EFFECT OF AXIAL SPACING ON COMPRESSOR STABILITY

Experimental studies are carried out at a low speed axial compressor with five different rotor/stator gaps. Analysis of the effect of axial spacing of two successive blade rows on the measured mean flow coefficient at stall inception and on the flow range of compressor under multi-cell rotating stall operating conditions proves that the stator can suppress the flow disturbance in the compressor and strengthen the stability of the compressor. Experimental data show that the stall flow coefficient decreases by reducing the axial spacing of successive blade rows. Moreover, by reducing the axial spacing, the stall pattern transition pace from multi-cell stall to single-cell stall can be shifted. And the compressor directly slips into single-cell stall at 21.0% CR axial spacing. By analyzing the pressure fluctuation closed to the surge line, it can be known that there exists an eigenfrequency where the amplitude of the oscillating pressure suddenly and dramatically increases as the compressor runs close to the surge line and this pressure disturbance is relevant to the compressor instability.

OPTIMUM OF PRESSURE RATIOS OF MULTI-STAGE RECIPROCATING COMPRESSOR WITH PRACTICAL INTER-COOLING

The optimum pressure ratio distribution of a multistage reciprocating compressor is presented based on the assumption, i.e. the inter stage cooling is perfect and there are no pressure losses. The optimization of the two or three stage pressure ratio is analyzed in two cases of constant heat transfer rate for the inter cooler or constant inter stage inlet temperature, based on the minimum of the sum of theoretical compression power at each stage about a multi stage reciprocating compressor. Furthermore, with an example of two stage compressor the influence on the sum of the power of each stage is analyzed when practical pressure ratio deviates from the optimum value. It is obtained that under different cooling conditions the optimum pressure ratio distribution of the multi stage compression is various, and the change of the optimum pressure ratio within a small range has little influence on the sum of the power each stage. For the two stage compression, this range can be represented as ε 1=(0 96～1 06)ε 1j .

Design and Key Technology of Oil-Free Centrifugal Air Compressor for Hydrogen Fuel Cell

For a 120 kW hydrogen fuel cell system,a centrifugal air compressor with fixed power of 22 kW fuel cell is designed.Firstly,the theoretical calculation is carried out for the aerodynamic characteristics of a ultra-high-speed permanent magnet synchronous motor,an air compressor,and an aerodynamic foil bearing.Then,a prototype is trial-produced and a related test bench is built for test verification.Finally,both the simulation and test results indicate that the designed centrifugal air compressor meets the overall requirements of the hydrogen fuel cell system,and the relevant conclusions provide both theoretical and experimental references for the subsequent series development and design of the centrifugal air compressor.

Development of High Efficiency Swing Compressor for R32 Refrigerant

In the age of global warming, energy saving features and overall reduction of environmental impact are critical components that must be addressed when developing new HVAC （heating ventilation and air conditioning） units. We chose R32 refrigerant, with its lower LCCP （life cycle climate performance） as a more sustainable choice than R410A. However, R32 has its drawbacks. Due to its smaller molecular weight, internal leakage loss is higher for R32. Moreover, high discharge gas temperature decreases the reliability of the compressor, and makes a large overheating loss increase. In this study, we will describe the technologies （reducing the piston pressurizing force, heat-insulating structure, optimizing the port diameter） that were developed to overcome these drawbacks. We will also oresent the performance and reliability of the newly develoned high efficiency swing, comnressor series for R32 refrigerant.

Influence of Different Equations of State on Simulation Results of Supercritical CO_(2) Centrifugal Compressor

Supercritical CO_(2)(SCO_(2))Brayton cycle has received more and more attention in the field of power generation due to its high cycle efficiency and compact structure.SCO_(2) compressor is the core component of the cycle,and the improvement of its performance is the key to improving the efficiency of the entire cycle.However,the operation of the SCO_(2) compressor near the critical point has brought many design and operation problems.Based on the Reynolds Averaged Navier-Stokes(RANS)model,the performance and flow field of SCO_(2) centrifugal compressors based on different CO_(2) working fluid models are numerically investigated in this paper.The stability and convergence of the compressor steady-state simulation are also discussed.The results show that the fluid based on the Span-Wanger(SW)equation can obtain a more ideal compressor performance curve and capture a more accurate flow field structure,while the CO_(2) ideal gas is not suitable for the calculation of SCO_(2) centrifugal compressors.But its flow field can be used as the initial flow field for numerical calculation of centrifugal compressor based on CO_(2) real gas.

Review on Stress Corrosion and Corrosion Fatigue Failure of Centrifugal Compressor Impeller

Corrosion failure,especially stress corrosion cracking and corrosion fatigue,is the main cause of centrifugal compressor impeller failure.And it is concealed and destructive.This paper summarizes the main theories of stress corrosion cracking and corrosion fatigue and its latest developments,and it also points out that existing stress corrosion cracking theories can be reduced to the anodic dissolution（AD）,the hydrogen-induced cracking（HIC）,and the combined AD and HIC mechanisms.The corrosion behavior and the mechanism of corrosion fatigue in the crack propagation stage are similar to stress corrosion cracking.The effects of stress ratio,loading frequency,and corrosive medium on the corrosion fatigue crack propagation rate are analyzed and summarized.The corrosion behavior and the mechanism of stress corrosion cracking and corrosion fatigue in corrosive environments,which contain sulfide,chlorides,and carbonate,are analyzed.The working environments of the centrifugal compressor impeller show the behavior and the mechanism of stress corrosion cracking and corrosion fatigue in different corrosive environments.The current research methods for centrifugal compressor impeller corrosion failure are analyzed.Physical analysis,numerical simulation,and the fluid-structure interaction method play an increasingly important role in the research on impeller deformation and stress distribution caused by the joint action of aerodynamic load and centrifugal load.

Fluid-structure Interaction Analysis and Lifetime Estimation of a Natural Gas Pipeline Centrifugal Compressor under Near-choke and Near-surge Conditions

Up to present, there have been no studies concerning the application of fluid-structure interaction（FSI） analysis to the lifetime estimation of multi-stage centrifugal compressors under dangerous unsteady aerodynamic excitations. In this paper, computational fluid dynamics（CFD） simulations of a three-stage natural gas pipeline centrifugal compressor are performed under near-choke and near-surge conditions, and the unsteady aerodynamic pressure acting on impeller blades are obtained. Then computational structural dynamics（CSD） analysis is conducted through a one-way coupling FSI model to predict alternating stresses in impeller blades. Finally, the compressor lifetime is estimated using the nominal stress approach. The FSI results show that the impellers of latter stages suffer larger fluctuation stresses but smaller mean stresses than those at preceding stages under near-choke and near-surge conditions. The most dangerous position in the compressor is found to be located near the leading edge of the last-stage impeller blade. Compressor lifetime estimation shows that the investigated compressor can run up to 102.7 h under the near-choke condition and 200.2 h under the near-surge condition. This study is expected to provide a scientific guidance for the operation safety of natural gas pipeline centrifugal compressors.

Time-dependent Vibration Frequency Reliability Analysis of Blade Vibration of Compressor Wheel of Turbocharger for Vehicle Application

Blade vibration failure is one of the main failure modes of compressor wheel of turbocharger for vehicle application. The existing models for evaluating the reliability of blade vibration of compressor wheel are static, and can not reflect the relationship between the reliability of compressor wheel with blade vibration failure mode and the life parameter. For the blade vibration failure mode of compressor wheel of turbocharger, the reliability evaluation method is studied. Taking a compressor wheel of turbocharger for vehicle application as an example, the blade vibration characteristics and how they change with the operating parameters of turbocharger are analyzed. The failure criterion for blade vibration mode of compressor wheel is built with the Campbell diagram, and taking the effect of the dispersity of blade natural vibration frequency and randomness of turbocharger operating speed into account, time-dependent reliability models of compressor wheel with blade vibration failure mode are derived, which embody the parameters of blade natural vibration frequency, turbocharger operating speed, the blade number of compressor wheel, life index and minimum number of resonance, etc. Finally, the rule governing the reliability and failure rate of compressor wheel and the method for determining the reliable life of compressor with blade vibration is presented. A method is proposed to evaluate the reliability of compressor wheel with blade vibration failure mode time-dependently.

Separation control using synthetic vortex generator jets in axial compressor cascade

An experimental investigation conducted in a high-speed plane cascade wind tunnel demonstrates that unsteady flow control by using synthetic （zero mass flux） vortex generator jets can effectively improve the aerodynamic performances and reduce （or eliminate） flow separation in axial compressor cascade. The Mach number of the incoming flow is up to 0.7 and most tested cases are at Ma = 0.3. The incidence is 10° at which the boundary layer is separated from 70% of the chord length. The roles of excitation frequency, amplitude, location and pitch angle are investigated. Preliminary results show that the excitation amplitude plays a very important role, the optimal excitation location is just upstream of the separation point, and the optimal pitch angle is 35°. The maximum relative reduction of loss coefficient is 22.8%.

Valve Dynamic and Thermal Cycle Model in Stepless Capacity Regulation for Reciprocating Compressor

The existing researches of stepless capacity regulation system by depressing the suction valve for reciprocation compressor always adopt hypothesis that the compressor valves are open or close instantaneously, the valve dynamic has not been taken account into thermal cycle computation, the influence of capacity regulation system on suction valves dynamic performance and cylinder thermal cycle operation has not been considered. This paper focuses on theoretical and experimental analysis of the valve dynamic and thermal cycle for reciprocating compressor in the situation of stepless capacity regulation. The valve dynamics equation, gas forces for normal and back flow, and the cylinder pressure varying with suction valve unloader moment during compression thermal cycle are discussed. A new valve dynamic model based on L-K real gas state equation for reciprocating compressor is first deduced to reduce the calculation errors induced by the ideal gas state equation. The variations of valve dynamic and cylinder pressure during part of compression stroke are calculated numerically. The calculation results reveal the non-normal thermal cycle and operation condition of compressor in stepless capacity regulation situation. The numerical simulation results of the valve dynamic and thermal cycle parameters are also verified by the stepless capacity regulation experiments in the type of 3L-10/8 reciprocating compressor. The experimental results agree with the numerical simulation results, which show that the theoretical models proposed are effective and high-precision. The proposed theoretical models build the theoretical foundation to design the real stepless capacity regulation system.

Fuzzy comprehensive assessment of running condition for a large-scale centrifugal compressor set

A fuzzy comprehensive assessment method of running condition was constructed and applied to a large-scale centrifugal compressor set in a petrochemical corporation aiming at the monitoring and early warning of abnormal conditions in industry.The maximal information coefficient(MIC)correlation analysis of indexes was introduced to determine the independent indexes to be assessed,and the dynamic deterioration degree was calculated using the predicted independent indexes by the second-order Markov chain model.The fuzzy membership degree weighting method was employed to assess the running condition of all units in the set.Simple and direct radar chart was used to visualize condition assessment grades.Results showed that the proposed fuzzy comprehensive assessment method successfully assessed the running condition of the set.The constructed method achieved 10 min earlier alarm than the traditional threshold alarm occurred at the specific moment of00:44 on April 7 of 2018.The method would provide a valuable tool and have a wide engineering application in ensuring the safety and reliability of industrial production.

Numerical Simulation of Rotor Clocking Effect in a Low-Speed Compressor

Two-dimensional (2D) unsteady numerical simulation has been applied to studythe effect of the variation in relative circumferential positions of rotors on the performance of alow speed compressor. The result shows that the variation will change the relative position ofupstream rotor wake to the downstream rotor as well as the periodic and turbulent velocityfluctuations on the airfoils. When the upstream rotor wake impinges upon the leading edge of thedownstream rotor, the corresponding stage efficiency will be higher; when the upstream wake istransferred into the mid-passage of the downstream rotor, the corresponding stage efficiency will belower. The proper configuration of the relative position of rotors will cause obvious reduction inthe unsteady aerodynamic effect on the second rotor airfoils and improve the aerodynamic performanceof blades.

DISPLACEMENT CONTROL AND KINETIC ANALYSIS OF A NOVEL VARIABLE DISPLACEMENT COMPRESSOR FOR AUTOMOTIVE AIR CONDITIONER

A novel variable displacement compressor (VDC) for automotive air conditioner (AAC) is introduced, which inherits the advantages of common wobble plate type VDC. It has fewer parts and makes less noise, and instead of pneumatic valve the displacement is controlled by electronic control valve. In order to know the control mechanism well and get a good control effect, a mathematical model for the variable displacement mechanism is developed according to the geometrical and kinematical information of the compressor. Using the model, the effect of relevant parameters on variable displace control is estimated. It is helpful to make the optimum decision in the flow control of AAC. As the novel displacement control device, the structure and control rule of electronic control valve is introduced. It can get better effect than the conventional pneumatic valves. And by using this new electronic control device, the optimum systemic control of AAC is available.

Experimental Study of Stator Clocking Effects in an Axial Compressor

This paper is focused on the experimental study of the effects of stator clocking on the performance of a low-speed repeating stage axial compressor with compound-lean stators as well as the one with conventional stators （the baseline） for comparison. The experimental results show that as the clocking positions vary, the upstream stator wake enters the following passage at different circumferential positions, and then mixes with the local fluid in the following passage. This is the main reason for the variation of the compressor performance resulted from the stator clocking effects. The variation of the compressor performance due to the clocking effect is less pronounced for the compressor with compound-lean stators than with the baseline. At a certain clocking position, the efficiency of the compressor with compound-lean stators is increased in comparison with that of the baseline, especially on small mass flow rate conditions, e.g., 0.7% at design condition and 3.5% at near-surge condition in this case. The maximum 1.22% and the minimum 0.07% increases in efficiency on design condition are obtained through the combined effects of the stator compound-lean and the stator clocking in this case.