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Gas turbine technology 1600 1400 1200 1000 800 600 1930 Spey Conway Avon Whittle Derwent 1940 1950 1960 Trent RB211-524G/H RB211-535E4 RB211-624B4 RB211-524G2 RB211-22C 1980 1990 2000 Dart Year 1970 Figure 6. Development of turbine entry temperature (TET) with time. (DB-SPF) technique (figure 5). Production of these components is an exacting and onerous task, one that Rolls-Royce has met by constructing a purpose-built facility for the job, a facility that maintains a cleanliness regime beyond that of the electronics/microchip industry. Cleanliness during production is key because of the ‘stress raising’ effects that impurities and foreign particulates would have within the internal structure of the blade. Such point defects could initiate a fatigue crack that may propagate to failure under service conditions. When we consider the kinetic energy of a fan blade released at maximum revolution (remember the scenario of a small car launched very high. . . ) it can be seen that the expense of such a clean facility is a necessary one. On this front, however, we can be reassured that extensive testing and modelling has been completed to demonstrate that, if such an event were to occur, the engine shrouds and casings would not be compromised and no high energy debris would exit the engine. Indeed the aviation authorities demand that a complete engine ‘blade off’ test is completed for all new engine projects—necessary, but a multi-million pound engine is fit for little else afterwards. To complete this test a small explosive charge is attached to the root of one fan blade within the set. Then, once the engine has been powered up to full speed, the charge is detonated and the blade released. High speed cameras film the event from a variety of November 2003 positions and help to demonstrate that, apart from a large flame and some low energy material, nothing is released from the engine that might compromise an airframe’s integrity. Turbine blades A second key area of expertise for Rolls-Royce is within its turbine blade manufacturing facility. As stated earlier, there has been a clear trend in improved engine performance with time. In an effort to improve efficiencies, weight must be shed from the construction and operating temperature must be increased. From the graph in figure 6 it can be seen that within 60 years the temperature of the gas Titanium alloy Aluminium alloy Temperature Figure 7. Specific strength versus temperature for a variety of common aero-engine materials. PHYSICS EDUCA TION 509 Nickel alloy Steel Specific strength Turbine entry temperature (°C)PDF Image | Gas turbine technology Rolls Royce
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