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tested for many types of turbomachine (4). This revealed that this level of stage loading could not be supported in reality, because with any acceptable number of blades the flow separated early on the suction surface near the hub (Fig. 5a) and late on the same surface near the tip (Fig. 5b), leading to considerable underturning. The structural analysis indicated that the blade and hub stresses were close to their limiting values, confirming the initial expectations for this blade speed. The design therefore had to be re-examined. A change of material was made to one of slightly higher strength (with a cost penalty), and with that and some further refinement to the rotor design it was decided that an increase in blade tip speed to 470 m/s could be managed. This reduced the stage loading to 1.12 and the approach flow angle to 13.9°. This meant that the rotor inlet blade angle could be set at about 25° to maintain the incidence adequately negative. Additional work output to achieve the design target was gained by allowing the rotor exit whirl to increase to just over 20°, which is about the limit for effective pressure recovery in an exhaust diffuser. The rotor exit hub radius had to be increased to allow the blades to be thickened. The result is summarized in column B of Table 1. The total-to-total efficiency of the new design was predicted to be just over 1% higher than that of the old, but the total-to-static efficiency is slightly lower because the more restricted exducer increases the rotor exit kinetic energy. The effects of incidence have not been completely eliminated and there remains a small region of separation in the hub-suction surface corner (Fig. 6a), this is much smaller than before and does not affect the remainder of the flow field. The flow near the tip of the blade (Fig. 6b) is quite uniform and the deviation is reduced to a very small amount. ALTERNATIVE TURBINE ROTOR MATERIALS The alternative route to high levels of turbine output power is through the development of new rotor materials. The industry standard for many years has been the nickel-based alloys Inconel 713C or 713LC, which combine excellent creep resistance at high temperatures with good casting properties and an acceptable cost. Other materials are worthy of consideration and in some cases are under active consideration in the quest, not only for higher blade speeds, but also reductions in mass and inertia. Some of these are listed, together with relevant properties, in Table 2. The baseline is IN713LC. IN718 is of similar composition, but it is a wrought alloy that offers significantly higher fatigue strength at high temperatures. It is widely used for disks in gas turbines that are exposed to moderate temperatures, but is not usually considered to offer any advantages for turbochargers except for a few specialty applications where cost is not a principal consideration. A number of other material have also been developed for high temperature gas turbine applications. CM MAR-M-247LC is one such material that is used in at least one turbocharger application. The specific strength of this material is similar to that of IN713LC but the specific stiffness is much higher. This suggests that thinner blades might be used to aerodynamic advantage while maintaining an adequate high cycle fatigue life. The material is slightly more dense than IN713LC but with thinner blade sections the overall rotor mass and inertia are likely to be about the same. The principal drawback of this material is the additional cost.PDF Image | HIGH BOOST TURBOCHARGERS radial and mixed flow turbines
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