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Proceedings of: ASME TURBOEXPO 2004 June 14-17, 2004, Vienna, Austria GT-2004-54205 Design of Ceramic Components for an Advanced Micro-turbine Engine Bill Tredway, Jun Shi, John Holowczak, Venkata Vedula, Connie E. Bird, S. Scott Ochs, Luca Bertuccioli, David J. Bombara and Kevin E. Green United Technologies Research Center, East Hartford, CT ABSTRACT Ceramic components, due to their high temperature capability, allow significantly higher turbine inlet temperatures with minimal cooling. Hot-section engine components, including combustor, integral vane ring, integrally bladed turbine rotor, and turbine tip shroud were designed for an advanced micro-turbine engine, with special attention to attachment methods that minimize thermal stresses due to large differences between coefficients of thermal expansion between metallic and ceramic materials. Detailed aerodynamic, thermal and stress analyses were performed. Both steady state and transient conditions were evaluated to guide design decisions that lead to optimal component reliability and manufacturability. This paper describes the component design, analysis, and fabrication experiences with silicon based monolithic ceramic materials. INTRODUCTION The recent massive blackout in North America highlighted the vulnerability of the current electric grid system for reliable distribution of electric power [1]. The blackout on August 14, 2003, affected 50 million people in eight U.S. states and eastern Canada. Billed as the worst blackout in America’s history, it cost at least $6 billion in economic and other losses. The U.S. Department of Energy (DOE) had foreseen the potential problems with antiquated power distribution systems and initiated an Advanced Micro-turbine Systems program [2]. Under this program, electric generators driven by high efficiency micro-turbine engines are developed to provide electric power local to power demands, thereby relieving the reliance on electricity grids that are already congested and are costly to maintain and upgrade. United Technologies Research Center and Pratt and Whitney recognized the market potential for micro-turbine engines for distributed power generation and were awarded a DOE contract to develop a high thermal efficiency (>40%) and low installed cost (<$500/kW) ST5+ micro-turbine with a power output of 400kw [3]. A key improvement to the advanced micro-turbine is application of structural ceramics to hot gas path components: combustor, first stage turbine vanes, integrally bladed rotor (IBR), and turbine tip shroud. Together, these ceramic components account for 3% increase in engine thermal efficiency relative to the baseline ST5 engine. A picture of the ST5+ micro-turbine with its major components are shown in Figure 1. Engine specifications and early work on the design, analysis and fabrication of these components were reported in a previous paper [4]. This paper describes more recent development efforts. Figure 1: Baseline ST5 micro-turbine engine CERAMIC COMBUSTOR Metal combustor cans are either film cooled (earlier gas turbine engines) or impingement cooled (more recent engines) to maintain structural integrity under severe thermal loading. In both cases, the cooled combustor wall leads to local quenching of CO burnout, thereby resulting in high (toxic) CO emissions. In addition, active film cooling of the combustor wall also introduces flow losses that are detrimental to engine performance. By using high temperature ceramic materials, film or impingement cooling, CO quenching as well as the associated flow losses can be eliminated [5]. Elimination of the impingement cooling sleeve also represents a substantial cost saving, as the sleeve is fabricated with a large number of 106 Copyright © 2004 by ASMEPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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