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Cooled Cooling Air As the maximum combustion temperatures in engines increase, the hot sections of the engine require new high-temperature materials, greater cooling by air bled from the high-pressure compressor, and more-effective cooling schemes. Bleeding more compressed air to cool components is not an ideal solution because this decreases the engine’s thermodynamic efficiency by removing air (which has al- ready been compressed) from the combustion process. One way to reduce the amount of cooling air that is required is to use cooled cooling air (CCA). However, the cooling air must be at a higher pres- sure than the combustion products flowing through the turbine, and because compressing the air also increases its temperature, the tem- perature of the bled air exiting the compressor increases with the OPR. In today’s engines, this “cooling” air can be well over 1,000oF. Therefore, by adding a heat exchanger to the engine that transfers energy from this very warm “cooling” air to the fuel, a smaller amount of cooling air would be needed. If this type of heat exchanger is added to future engines, it should improve the overall efficiency of those engines by extracting less cooling air, permitting higher per- formance (thrust-to-weight ratio) through higher RITs or providing better life expectancy for engine parts. However, the heat exchanger will add to the engine’s complexity, part count, weight, and vulner- ability to being detected, and it will add to the heat load on the air- craft’s fuel.6 Thus, cooling the cooling air will affect development, production, and O&S costs. Advanced Materials The selection of materials for jet engines plays a primary role in de- termining the performance, weight, life, and costs of these systems. Early engines were mostly made of steel. Today’s engines are made of a variety of materials, including high-temperature nickel-based superalloys, titanium, aluminum, steel, composites, and ceramics. ______________ 6Friction between the cooling air and the heat exchanger’s internal air passages will reduce the pressure of the cooling air slightly, which may lead to some of the cooling air needing to be in a small auxiliary compressor, further adding to the engine’s part count and complexity. Trends in Technological Innovation 35PDF Image | Military Jet Engine Acquisition Technology Basics and Cost-Estimating Methodology
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