Novel Method for Evaluating the Aging of Aviation Turbine Engine Oils via High-Temperature Bearing Deposit Tests

Aviation turbine engine oils require excellent thermal-oxidative stability because of their high-temperature environments.High-temperature bearing deposit testing is a mandatory method for measuring the thermal-oxidative performance of aviation lubricant oils,and the relevant apparatus was improved in the present study.Two different commercial aviation turbine engine oils were tested,one with standard performance(known as the SL oil)and the other with high thermal stability,and their thermal-oxidative stability characteristics were evaluated.After 100 h of high-temperature bearing testing,the SL oil was analyzed by using various analytical techniques to investigate its thermal-oxidative process in the bearing test,with its thermal-oxidative degradation mechanism also being discussed.The results indicate that the developed high-temperature bearing apparatus easily meets the test requirements of method 3410.1 in standard FED-STD-791D.The viscosity and total acid number(TAN)of the SL oil increased with the bearing test time,and various deposits were produced in the bearing test,with the micro-particles of the carbon deposits being sphere-like,rod-like,and sheet-like in appearance.The antioxidant additives in the oil were consumed very rapidly in the first 30 h of the bearing test,with N-phenyl-1-naphthylamine being consumed faster than dioctyldiphenylamine.Overall,the oil thermal-oxidative process involves very complex physical and chemical mechanisms.

Preparation and characterization of LPPS NiCoCrAlYTa coatings for gas turbine engine

NiCoCrAlYTa coatings have been deposited onto an aircraft gas turbine engine blade using a LPPS unit equipped with a computerized robot. Optimal processing conditions, including spray parameters, the trajectory of the robot, and the synchronized movements between the torch and the blade, have been developed for superior coating properties. Transferred arc treatment, providing a preheating and a cleaning of the substrate surface, enhances the adherence of the coatings to the substrate. The resulting LPPS coatings show dense and uniform characteristics with ideal hardness, and good corrosion resistance to cycle oxidation.

Effects analysis on catalytic combustion characteristic of hydrogen/air in micro turbine engine by fuzzy grey relation method

In order to enhance catalytic combustion efficiency, a premixed hydrogen /air combustion model of the micro turbine engine is established under different excess air ratio, inlet velocity and heat transfer coefficient. And effects of inlet velocity, excess air coefficient and heat transfer coefficient on the catalytic combustion efficiency of the hydrogen have been analyzed by the FLUENT with CHEMKIN reaction mechanisms and the fuzzy grey relation theory. It is showed that inlet velocity has a more intuitive influence on the catalytic combustion efficiency of the hydrogen. A higher efficiency can be obtained with a lower inlet velocity. The optimum excess air coefficient is in the range of 0.94 to 1.0, the catalytic combustion efficiency of the hydrogen will be declined if the excess air coefficient exceeded 1.0. The effect of heat transfer coefficient on the catalytic combustion efficiency of the hydrogen mainly embodies in the case of the excess air coefficient exceeded 1.0, however, the effect will be declined if the heat transfer coefficient exceeded 4.0. The fuzzy grey relation degrees of the inlet velocity, heat transfer coefficient and excess air coefficient on the catalytic combustion efficiency of the hydrogen are 0.640945, 0.633214 and 0.547892 respectively.

RELIABILITY ANALYSIS FOR AN AERO ENGINE TURBINE DISK UNDER LOW CYCLE FATIGUE CONDITION

Reliability analysis methods based on the linear damage accumulation law (LDAL) and load-life interference model are studied in this paper. According to the equal probability rule, the equivalent loads are derived, and the reliability analysis method based on load-life interference model and recurrence formula is constructed. In conjunction with finite element analysis (FEA) program, the reliability of an aero engine turbine disk under low cycle fatigue (LCF) condition has been analyzed. The results show the turbine disk is safety and the above reliability analysis methods are feasible.

Fault Identification and Health Monitoring of Gas Turbine Engines Using Hybrid Machine Learning-based Strategies

Ahealth monitoring scheme is developed in this work by using hybrid machine learning strategies to iden-tify the fault severity and assess the health status of the aircraft gas turbine engine that is subject to component degrada-tions that are caused by fouling and erosion.The proposed hybrid framework involves integrating both supervised recur-rent neural networks and unsupervised self-organizing maps methodologies,where the former is developed to extract ef-fective features that can be associated with the engine health condition and the latter is constructed for fault severity modeling and tracking of each considered degradation mode.Advantages of our proposed methodology are that it ac-complishes fault identification and health monitoring objectives by only discovering inherent health information that are available in the system I/O data at each operating point.The effectiveness of our approach is validated and justified with engine data under various degradation modes in compressors and turbines.

PID Parameters for Tuning and Optimization of a Turbine EngineBased on the Simplex Search Method

A PID parameters tuning and optimization method for a turbine engine based on the simplex search method was proposed. Taking time delay of combustion and actuator into account, a simulation model of a PID control system for a turbine engine was developed. A performance index based on the integral of absolute error （IAE） was given as an objective function of optimization. In order to avoid the sensitivity that resulted from the initial values of the simplex search method, the traditional Ziegler-Nichols method was used to tune PID parameters to obtain the initial values at first, then the simplex search method was applied to optimize PID parameters for the turbine engine. Simulation results indicate that the simplex search method is a reasonable and effective method for PID controller parameters tuning and optimization.

A DEMATEL Approach Based on Fuzzy Sets for Evaluating Critical Factors of Gas Turbine in Marine Engineering

In power production,gas turbines are commonly used components that generate high amount of energy depending on size and weight.They function as integral parts of helicopters,aircrafts,trains,ships,electrical generators,and tanks.Notably,many researchers are focusing on the design,operation,and maintenance of gas turbines.The focal point of this paper is a DEMATEL approach based on fuzzy sets,with the attempt to use these fuzzy sets explicitly.Using this approach,the cause–effect diagram of gas turbine failures expressed in the literature is generated and aimed to create a perspective for operators.The results of the study show that,"connecting shaft has been broken between turbine and gear box"selected the most important cause factor and"sufficient pressure fuel does not come for fuel pump"is selected the most important effect factor,according to the experts.

Gas Turbine Design and Matching Research of Waste Heat Recovery System for Marine Diesel Engine

With the emphasis on energy and environmental protection,energy-conservation and emission-reduction become vital issues for industrial development.Moreover,with the development of legislation on marine environment,the marine diesel engine has become focusing on energy saving and emission reduction for ships.For low-speed diesel engines under high load,waste heat from exhaust gas can be recovered by the compact and efficient gas turbine.In this paper,the matching design research between low speed diesel engine and gas turbine is carried out.To balance efficiency and compactness,the impeller was adjusted and generated by ANSYS BLADEGEN,based on 1D thermodynamic design.And the 1D calculation is similar to the ANSYS CFX simulation result:the total-static efficiency is 73.8%compared to 76.7%.Moreover,the flow separation happened at the impeller suction side and created vortex due to the high incidence angle.The off-design operating point simulation of the turbine shows though the pressure ratio increase will cause the efficiency to decline a little,the total shaft power rises.In sum,this paper worked out a power turbine suitable for a low-speed diesel engine according to the turbine character matching design and simulation,which provides foundation to the construction of a steady operation of waste heat recovery system for marine diesel engine.

Reheat effect on the improvement in efficiency of the turbine driven by pulse detonation

Due to the strong unsteadiness of pulse detonation,large flow losses are generated when the detonation wave interacts with the turbine blades,resulting in low turbine efficiency.Considering that the flow losses are dissipated into the gas as heat energy,some of them can be recycled during the expansion process in subsequent stages by the reheat effect,which should be helpful to improve the detonationdriven turbine efficiency.Taking this into account,this paper developed a numerical model of the detonation chamber coupled with a two-stage axial turbine,and a stoichiometric hydrogen-air mixture was used.The improvement in turbine efficiency attributable to the reheat effect was calculated by comparing the average efficiency of the stages with the efficiency of the two-stage turbine.The research indicated that the first stage was critical in suppressing the flow unsteadiness caused by pulse detonation,which stabilized the intake condition of the second stage and consequently allowed much of the flow losses from the first stage to be recycled,so that the efficiency of the two-stage turbine was improved.At a 95%confidence level,the efficiency improvement was stable at 4.5%—5.3%,demonstrating that the reheat effect is significant in improving the efficiency of the detonation-driven turbine.

基于Pro/Engineer的风动水泵叶片结构优化设计

运用软件对矿用风动水泵涡轮叶片进行了三维造型设计 ,通过灵敏度分析、可行性分析以及最优化设计 ,确定了水轮叶片的最佳结构参数。

Development of Optimal Maintenance Policies for Offshore Wind Turbine Gearboxes Based on the Non-homogeneous Continuous-Time Markov Process

Gearbox in offshore wind turbines is a component with the highest failure rates during operation. Analysis of gearbox repair policy that includes economic considerations is important for the effective operation of offshore wind farms. From their initial perfect working states, gearboxes degrade with time, which leads to decreased working efficiency. Thus, offshore wind turbine gearboxes can be considered to be multi-state systems with the various levels of productivity for different working states. To efficiently compute the time-dependent distribution of this multi-state system and analyze its reliability, application of the nonhomogeneous continuous-time Markov process(NHCTMP) is appropriate for this type of object. To determine the relationship between operation time and maintenance cost, many factors must be taken into account, including maintenance processes and vessel requirements. Finally, an optimal repair policy can be formulated based on this relationship.

Wells Turbine for Wave Energy Conversion —Improvement of the Performance by Means of Impulse Turbine for Bi-Directional Flow

Wells turbine has inherent disadvantages in comparison with conventional turbines: relative low efficiency at high flow coefficient and poor starting characteristics. To solve these problems, the authors propose Wells turbine with booster turbine for wave energy conversion, in order to improve the performance in this study. This turbine consists of three parts: a large Wells turbine, a small impulse turbine with fixed guide vanes for oscillating airflow, and a generator. It was conjectured that, by coupling the two axial flow turbines together, pneumatic energy from oscillating airflow is captured by Wells turbine at low flow coefficient and that the impulse turbine gets the energy at high flow coefficient. As the first step of this study on the proposed turbine topology, the performance of turbines under steady flow conditions has been investigated experimentally by model testings. Furthermore, we estimate mean efficiency of the turbine by quasi-steady analysis.

Analysis of Emissions Profiles of Hydraulic Fracturing Engine Technologies

Today, the oil and gas industry, and in particular hydraulic fracturing operations, have come under increasing pressure from regulators and the public to reduce emissions. As the industry evolves, oil and gas producers are in the position of evaluating alternative technologies which will support their objectives of reducing their overall emissions profile and carbon footprint. As a response, the deployment of technology and solutions to reduce emissions related to hydraulic fracturing applications has recently accelerated, creating various options to address these industry challenges. BJ Energy Solutions and West Virginia University have been working on the application and emissions characterization of various hydraulic fracturing technologies. A study was conducted to evaluate the efficiency and resultant emissions from various technologies, including natural gas reciprocating engines, diesel-natural gas dual-fuel engines, large (>24 MW) gas turbines, and direct drive turbines. The study involved the development of an emissions model with the purpose of estimating total emissions of carbon dioxide (CO2), nitrous oxide (N2O) and exhaust methane (CH4) slip, all Greenhouse Gases (GHGs), and converted to tons of CO2 equivalent emissions per day of operation. The model inputs are the required Hydraulic Horsepower (HHP) based on pumping rate and pressure for various shale play scenarios. The model calculates emissions from the TITAN, which is a direct-drive turbine model fielded by BJ, using data collected following U.S. Environmental Protection Agency (EPA) testing protocols. The model also calculates and compares other hydraulic fracturing technologies utilizing published Original Equipment Manufacturer (OEM) data. Relevant EPA-regulated criteria emissions of oxides of nitrogen (NOx), Carbon Monoxide (CO) and Particulate Matter (PM) are also reported. Modeling results demonstrated that in most cases, the TITAN gas turbine system has lower total GHG emissions than conventional diesel and other next-generation technologies, and also has lower criteria emissions. The benefits of the TITAN gas turbine system compared to the other technologies stems from significantly lower methane slip, and the high-power transfer efficiency resulting from directly connecting a turbine to a reciprocating pump, despite the comparatively lower thermal efficiency.

A Strategy to Control the Turbocharger Energy of a Diesel Engine at Different Altitudes

Power deterioration is a major problem for diesel engines operating at high altitudes.This problem stems from the limited availability of turbocharger energy,which is not enough to increase the boost pressure to the required level.In this study,a control strategy is introduced in order to achieve engine power recovery at different altitudes.It is shown that as the altitude increases from 0 to 4500 m,the required boost pressure ratio increases from 2.4 to 4.3.The needed turbocharger energy should be increased accordingly by 240%,and the TCC(turbine characterization coefficient)should be adjusted within wide ranges.A 12%decrease in the TCC can lead to a rise of the intake air pressure,which can compensate the pressure decrease due to a 1000 m altitude increase.The fluctuation range of boost pressure was within 14.5 kPa for variations in altitude from 0 to 4500 m.

Parameterization Modeling of a Gas Turbine Coverplate

In order to reduce product development cycle time, aerospace companies tend to develop various correlations integrating geometric and performance parameters. This paper covers the development of a parameterization modeling, to be used in the preliminary design phase, for the turbine cover plate of an aero-engine. The parameterization modeling of the turbine cover plate is achieved by using commercial CAD （computer aided design） software processing in batch mode. Two main approaches are presented the outer face and the skeleton models. These models can then be integrated into an iterative process for designing optimal shapes. Both models are capable of reproducing existing cover plate with reasonable accuracy in relatively shorter time periods. However, the skeleton approach provides probably the best results in terms of flexibility and accuracy, but increases programming complexity and requires greater run times.

Application of ultrasonic fatigue technology in very-high-cycle fatigue testing of aviation gas turbine engine blade materials:A review

The need for very-high-cycle fatigue(VHCF)testing up to 1010cycles of aviation gas turbine engine blade materials under combined mechanical loads and complex environments has encouraged the development of VHCF testing instrumentation and technology.This article begins with a comprehensive review of the existing available techniques that enable VHCF testing.Recent advances in ultrasonic fatigue testing(UFT)techniques are highlighted,containing their new capabilities and methods for single load,multiaxial load,variable amplitude fatigue,and combined cycle fatigue.New techniques for conducting UFT in high-temperature,humid environments,and corrosive environments are summarized.These developments in mechanical loading and environmental building techniques provide the possibility of laboratory construction for real service conditions of blade materials.New techniques that can be used for in situ monitoring of VHCF damage are summarized.Key issues in the UFT field are presented,and countermeasures are collated.Finally,the existing problems and future trends in the field are briefly described.

Power System Analysis of an Aero-Engine

The aim of this study is analyzed in detail for better understanding of energy and power of an aero-engine. In this regard, this study presents energy equations were applied to the turbofan engine components. The engine has a thrust range of 82 to 109 kN. It consists of fan, axial low pressure compressor (LPC), axial high pressure compressor (HPC), an annular combustion chamber, high-pressure turbine (HPT) and low pressure turbine (LPT). The results show that power of the engine flow approaches a maximum value to be 82.85 MW in the combustor outlet, while minimum power is observed at LPC inlet with the value of 1.37 MW. Furthermore, important parameters of the engine are also analyzed from reverse-engineering method. It is expected that results of this study will be beneficial of power, cogeneration and aero-propulsive generation systems in similar environment.

Auto-updating model-based control for thrust variation mitigation and acceleration performance enhancement of gas turbine aero-engines

Model-based control shows promising potential for engine performance improve-ment and future aero-propulsion requirements.In this paper,an auto-updating thrust variation mitigation(AuTVM)control approach using on-board model strategies is proposed for gas tur-bine aero-engines under in-service degradation effects,which aims at active thrust regulation and acceleration protection in a simultaneous way.The AuTVM control is integrated with an on-line block,based on a reliable on-board engine model,and an off-line part for the periodical update of control parameters via post-flight engine monitoring data.The core feature of the AuTVM control is a set of auto-updating loops within the on-line part,including thrust regu-lation loop,surge margin loop,turbine entry temperature loop,and the steady loop,whose con-trol parameters are periodically adjusted with increasingflight cycles.Meanwhile,an industrial sensor-based baseline controller and two tailored model-based controllers,i.e.,a thrust variation mitigation(TVM)controller withfixed gains and a self-enhancing active transient protection(SeATP)controller with pro-active transient protection and passive thrust control,are also developed as comparison bases.Numerical simulations for idle to full-power acceleration tests are carried on a validated aero-thermal turbofan engine model using publicly available degra-dation data.Simulation results demonstrate that both new engines and severely degraded en-gines regulated by the AuTVM controller show significant thrust response enhancement,compared to the baseline controller.Moreover,thrust variation at the maximum steady state of degraded engines,which exists within the SeATP controller and the baseline controller,is suppressed by the proposed AuTVM controller.Robustness analysis against degradation uncer-tainties and sensor accuracy confirms that the AuTVM controller owns a closer maximum steady-state thrust distribution to the desired value than those of the SeATP and the baseline controller while utilizing transient margins of controlled engines more effectively.Hence,the control performance of the AuTVM controller for in-service engines is guaranteed.

Evaluation of service-induced microstructural damage for directionally solidified turbine blade of aircraft engine

Turbine blades of gas turbine engines usually suffer from severe operational conditions characterized by high temperature and stress. Severe operational conditions during service cause microstructural changes in turbine blades and degrade their mechanical properties. In this study, service-induced microstructural damages in serviced turbine blades manufactured from a directionally solidified superalloy were evaluated. The observed microstructural damage of the turbine blade mainly involves the coarsening and rafting of γ' precipitates. The leading edge of 60% height of the turbine blades undergone most severe microstructural damage with significant microstructural evolution at this area. Microstructural damage affects the mechanical properties such as Vickers hardness, that is,Vickers hardness decreases as the equivalent diameter decreases. Microstructural damage shows great positiondependent feature as service temperature and radial stress on blade changes. With the aid of energy-dispersive spectrometer(EDS) analysis on carbide, the transformation of carbide does not exist. In addition, no topological closed-packed phase exists in the turbine blade.