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2.1.2.1 Ceramic Vane Ring The thermal gradients and the resulting thermoelastic stresses in the vane cascade were estimated using finite element analysis. The ST5 metal design, if manufactured as a single part from silicon nitride, was used for this initial analysis. Finite element analysis was performed for the complete vane ring (13 vanes) by ABAQUS using 4-node tetrahedral elements. Thermal boundary conditions for ST5 vanes were obtained from Pratt & Whitney Canada (PWC) and were used in the analysis. The maximum and minimum temperatures in the vane assembly were 2018 and 1642°F respectively and the maximum principal stress was 25.8 ksi at the inner surface of the inner platform. The analysis was performed for several different boundary conditions that result in more severe gradients and stresses. It was found that the thermal stresses could be as high as 63 ksi depending on the severity of the heat transfer coefficients and sink temperatures. FEA was performed to predict the steady state thermal gradients and the resulting thermoelastic stresses in a Gen 2 vane design consisting of 15 vanes. A count of 15 vanes was consistent with the aero meanline analysis, and was selected to avoid resonance with the 27 bladed rotor, while providing for the ability, if necessary, to use 5 vane triplets, or 3 five vane sections, to minimize parts count and sealing issues. The analysis indicated that the steady state stresses at the trailing edge of the vane were ~16 and 26 ksi for the average inlet and hot-streak conditions respectively. CARES analysis indicated that the corresponding probabilities of failure were 5.3 x 10-6 and 8.9 x 10-5, respectively, suggesting that these thermal stresses were acceptable for both conditions. The hoop stresses in the outer ring were less than 10 ksi, indicating that an integral continuous vane ring was viable. Transient analysis of the vane ring was performed for a variety of shutdown conditions. Initially, it was considered that the worst case scenario would be an instantaneous drop of T4 gas temperature to 1182 F (recuperator output) from 2100F. The analysis of this case showed that the maximum stresses in integral vane and separate outer platform designs were 37.2 and 29.8 ksi respectively. The analysis was also performed for the case when the gas temperature dropped to 1182F in 1 sec. For this case the stresses in the integral vane design and separate outer platform were 39.8 and 46.4 ksi respectively (Figure 2.1.7). In all cases, the transient stresses are highest at the trailing edge fillets. The reason for this is that the trailing edge cools much faster than the platforms resulting in a high temperature gradient at the fillets. Subsequently, mass flow data was obtained from PWC and was scaled by the aero- analysis to predict the variation of T3, T3.5, and T4 as a function of time. This data was used to predict the thermal stresses in the vane assembly. It was found that maximum stresses were higher than those predicted for step changes. The maximum stresses were 59 and 70 ksi for integral vane ring and separate outer platform designs, respectively. The corresponding probability of failure was ~20%. 25PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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