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Section 2.0 Advanced Microturbine System Technology Studies 2.1 Ceramic Turbine Technology Development The development of a ceramic intensive turbine was broken into several tasks, including aerodynamic design, design of silicon nitride turbine components (cT vane ring, integrally bladed rotor (IBR), and turbine shroud), attachment development for silicon nitride IBRs, assessment of environmental barrier coatings (EBCs) for ceramic turbine components, manufacturing development, and FOD resistance analytical development. This section of the report will summarize key progress in these areas. The majority of the design activity was completed prior to strategic redirection of the program away from the ST5; in those cases where the activity was incomplete, it is so noted in the report. Also, several papers on the ceramic component design activity were presented at major conferences during the timeframe of the AMS contract. Three of these papers for which manuscripts were prepared and submitted are included in the report Appendix for additional documentation. 2.1.1 Aerodynamic Design This task focused on aerodynamic design of Foreign Object Damage (FOD) resistant axial flow ceramic turbine vanes and rotor blades. The aerodynamic profiles of the cT turbine vanes and blades were altered to reduce blade count and thicken airfoil cross sections for improved producibility in silicon nitride and silicon carbide ceramics. The improved rotor blade shape and count were incorporated into the design for a ceramic IBR to replace the baseline ST5 rotor design. The baseline ST5 design incorporates uncooled, individual, single crystal superalloy blades. A silicon nitride ceramic IBR allowed for higher T4 temperatures while reducing overall systems cost by reducing parts count. Initial efforts focused on aerodynamic design of FOD resistant vanes and rotor blades, and structural design of a ceramic rotor hub. A meanline optimization was performed that resulted in a first-stage design consisting of 15 vanes and 27 blades. Axial chords were held to those of the baseline ST5 design to limit airfoil aspect ratios and the associated profile losses, while reaction was limited to 45% to reduce blade exit flow angle and Mach number, and the associated transition duct losses. This reaction is a substantial increase over that of the baseline, which was held to 25% to reduce the effects of combustion gas temperature on the uncooled single crystal superalloy vanes. Blade trailing edge thickness was increased for FOD resistance. The meanline optimization resulted in a design with an increase in aerodynamic stage efficiency of between 1 and 2 %-points over that of the baseline. The meanline data was converted to an initial three-dimensional design, which was optimized for pressure distribution using a steady, inviscid flow solver. The relative Mach number distribution at mid-span of this design can be seen in Figure 2.1.1. The initial aerodynamic design was then converted to CAD format and combined with the 20PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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