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platform distortion is 0.0018 in, comparable to the 0.0015 in turbine support casing distortion. Under the worst thermal loading case, i.e. the hot streak conditions, the peak thermal stress is just over 10 ksi in the shroud (see Figure 11). SUMMARY AND CONCLUSIONS Significant progress has been made in designing the ceramic components for ST5+ micro-turbine engine. It is believed that the three stationery components- combustor can, first stage vane ring and turbine shroud can meet the design requirements. However, it remains a challenge to design the ceramic IBR with acceptable stress and reliability. Prototype ceramic vane rings and turbine tip shrouds have been made and two of the silicon nitride vane rings meet the standards for rig testing. ACKNOWLEDGEMENTS The authors would like to thank DOE for its financial support and Debbie Haught of the DOE Office of Power Technologies and Stephen Waslo of the DOE Chicago Operations Office for their programmatic support. They also wish to acknowledge the technical support from their colleagues at Pratt & Whitney Canada. REFERENCES [1] Stauffer, J, 2003, August 14, 2003, “Blackout:Updated Sequence of Events”, Cambridge Energy Research Associates Report [2] U.S. Department of Energy, http://www.eere.energy.gov/ der/microturbines/microturbines.html#advanced [3] Rosfjord,T., “Advanced Microturbine Systems”, Progress Report for Period October 6, 2000 to December 31, 2000, for US Department of Energy. [4] Shi, J., V. Vedula, J. Holowczak, C. E. Bird, S. S. Ochs, L. Bertuccioli and D. J. Bombara, 2002, “Preliminary Design of Ceramic Components for the ST5+ Advanced Microturbine Engine”, ASME GT-2002-30547, ASME TURBOEXPO 2002, June 3-6, 2002, Amsterdam, The Netherlands [5] Smith, K.O. and Fahme, A, 1996, “Experimental assesment of the emissions benefits of a ceramic gas turbine combustor”, ASME Turbo Expo 1996, Paper 96-GT-318 [6] Brewer,D., Ojard,G. and Gibler,M., 2000, “Ceramic Matrix combustor liner rig test”, ASME Turbo Expo 2000, Munich, ASME 2000-GT-0670 [7] Verrilli, M.J., D. Brewer, 2002, “Characterisation of CMC fastners exposed in a combustor liner rig test”, ASME GT- 2002-30459 [8] Igashira, K., Matsuda, Y., 2001, “Development of the advanced combustor liner composed of CMC/GMC hybrid composite material”, ASME 2001-GT-0511 [9] Mikami, T., et al , 1996, “Status of the development of the CGT301, a 300KW Class Ceramic Gas Turbine”, ASME 96- GT-252. [10] Tatsumi, T., et al, 1999, “Development summary of the 300kw ceramic gas turbine CGT302”, ASME 99-GT-105 [11] Tanaka,R, T. Tatsumi, Y. Ichikawa, K. Sanbonsugi, 2001, “Development of the Hybrid Gas Turbine (1st year summary)”, ASME 2001-GT-0515 [12] Nemeth, N.N., Janosik, L.A, Gyekenyesi, J.P., "Ceramics Analysis and Reliability Evaluation of Structures/Life Prediction Program, Users and Programmers Manual", NASA Glenn Research Center, 1993. (a) (b) Figure 11: (a) Temperature distribution and (b) thermal stress distribution of the turbine shroud under hot streak conditions A second major design concern is the relative thermal deformation between the shroud and its support during engine operation. To analyze this, thermal growth of the casing and the ceramic shroud during startup and shutdown was predicted. During the –10F cold start, the turbine support casing is expected to shrink 0.015” more than the ceramic shroud, which means that a cold build clearance of at least 0.015” is needed. At steady state, the casing grows 0.010” more than the shroud, while during shutdown, 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. Contact stress considerations narrowed the design down to the one shown below. Because of the overall low stress in the shroud, siliconized silicon carbide (SiSiC) was considered. Figure 12 shows the initial manufacturing attempt by Schunk Co in Gissen, Germany. Figure 12: Ceramic turbine tip shroud 111 Copyright © 2004 by ASMEPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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