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shown in Figures 9 and 10 was developed, taking advantage of cyclic symmetry. ABAQUS FEA software was used to determine the centrifugal and thermal stresses. Convective heat transfer coefficients and sink temperatures were obtained from the aero-analysis to reflect ST5+ flow conditions. However, thermal boundary conditions for the disk front and rear surfaces and bore were based on the ST5, as flow conditions were not finalized yet. The stress distribution (Figure 10) is in good agreement with the 2D prediction. The maximum stress however is high in both cases. This is mainly caused by the introduction of the bore and to a lesser extent caused by a larger temperature gradient due to the hot blade. The rotor shape optimization to minimize maximum principal stress is in progress and the CARES/LIFE code will be used to predict the probability of failure. Figure 9. Temperature distribution (oC) from the 3D analysis Figure 10. Maximum principal stress (MPa) in a 3D analysis Foreign Object Damage Assessment A foreign object damage (FOD) assessment was preformed on the ST5+ rotor. The same analysis was also performed on the ST5 rotor to compare the FOD susceptibility of the two designs. For this analysis, the rotors were assumed to be made of AS800 silicon nitride from Honeywell Ceramic Components. The ST5+ rotor was designed with fewer, thicker blades, which have relatively large leading and trailing edge radii. The root fillet was also made as large as practically possible. The analysis was performed using DYNA3D software. A one-quarter disk with a single blade was modeled as shown in Figures 11 and 12. While the disk is rotating at speed, a 1.33 mm diameter zirconia particle weighing 0.007 gms entrained in the gas stream impacts the blade. This represents an event of TBC spallation from the combustor liner. The direction and speed of the particle were determined from the aero-analysis. An elastic material model with damage based on principal stress was used in the analysis. Elements were removed from the model when specified fracture strength was exceeded on two perpendicular planes. Gas shot test data was available and the damage model was calibrated to produce gas shot simulations that showed good agreement with the reported test results [15]. Figures 11 and 12 compare the damage incurred by the ST5 and ST5+ rotors subjected to an impact with the same size foreign object traveling at identical speeds. The foreign object penetrated all the way through the ST5 blade and rebounded from the ST5+ blade. It needs to be emphasized that this is a qualitative comparison of the extent of impact induced damage. The currently available damage models at UTRC do not include detailed fracture mechanics. It is likely that the damage shown in figure 11 would result in the loss of the trailing edge tip of the blade. 496 453 409 366 322 279 236 192 148 105 62 19 1010 963 916 868 820 773 726 679 631 584 536 488 442 103 Copyright © 2002 by ASME Figure 11. ST5 ceramic blade after particle impactPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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