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At steady state, the casing grows 0.010” more than the shroud, while during shut-down, the thin shroud reacts to gas temperature drop quickly, widening the gap between the shroud and the casing to 0.025”. Therefore the overlap between the tab on the shroud and the slot on the casing should be greater than 0.015” to maintain shroud support by the casing. There were pros and cons for both designs and a final design was not selected prior to the conclusion of the design activity. 2.1.2.3 Ceramic Turbine Rotor Two-dimensional disk only models were used to analyze the stress levels in the rotor, and the rotor bore. The 2D model was run repeatedly to arrive at an optimum disk shape that minimized bore and web stresses. Additionally it was desired to make the disk as symmetric as possible. Some material was added in the under rim fillet to balance the rim deflection. A solid disk design (with no bore) would have reduced disk stress, but the bore was required to allow for a path way for cooling air exiting from the air bearing to pass to the back side of the rotor. A 1” bore diameter was selected. Figure 2.1.12 shows 2D plots of the final disk design. The disk was reshaped to balance the rim radial deflection and to decrease web stress. The CARES code was used to predict probability of survival of the initial 3D design iteration. Those results indicated that high stress in the rim contributed more to the probability of failure than high stress in the bore. Based on this direction the disk was redesigned to allow for more bore stress and to reduce rim deflection. Figure 2.1.12 Radial deflection and maximum principle stress for a spinning disk only analysis The blade pull and thermal stress were than added to the 2D analysis. Figure 2.1.13 shows plots of temperature and maximum principal stress. It can be seen from the plot of maximum principal stress that the blade pull intensified the lower web stress more than the bore stress. The stress in the web is balanced. Stress in the lower web area is more tolerable that web stress near the rim due to increasing disk temperature from the bore to rim. The 2D blade pull and thermal effect model predicts bore stress of 61,000 psi. 32PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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