Objective
Objectives and content The European gas turbine industry must continue to improve its technical capabilities in order to compete with the US manufacturers, achieve ever-higher safety standards and comply with future environmental legislation. This 48 month RTD program, aimed at improved lifing methods for combustion chambers, is in direct response to the anticipated requirements for NOx reduction in aero gas turbines. Although the focus of the program is on combustors the technology will be generic, providing verified lifing methodology for the design and in-service support of all gas turbine components that are subjected to both creep and plasticity during every engine cycle. This activity is the subject of a targeted research action by the EIMG-TRA on Efficient and Environmentally Friendly Aircraft Propulsion, which is in preparation. Developing a new generation of combustors for improved efficiency and to meet the increasingly stringent NOx emissions requirements of legislation such as CAEP3 (Committee on Aviation Environmental Protection) will require a revolutionary change in design styles with the increased use of high stress concentration features such as angled effusion cooling holes. The introduction of new component concepts needs to be achieved without compromising safety and reliability or, critically from a commercial perspective, the early award of Extended Twin Operations clearance (ETOPS) for the aircraft. Meeting this goal requires a thorough understanding of material behaviour in representative geometries under realistic loading conditions. Stress and life predictions for combustors are extremely complex because the material can creep to such an extent at the high temperature end of the engine cycle that the residual stress at low temperatures causes reverse deformation by plasticity. Until recently the computing power required to run the necessary non-linear component analyses had not been available and therefore new designs were evolutionary, relying on previous engine experience.
This project aims to put into place design methods that fully exploit today's analysis capabilities based on three types of materials behaviour model:
- Constitutive models, implemented within the Finite Element (FE) codes used by each partner, to predict the stabilised component stress state as efficiently as possible;
- Crack initiation/damage models, based on parameters from the FE calculations, to predict component lives at the design stage;
- Crack growth models to allow safe inspection intervals to be specified where in-service problems exist.
Development of these models will require thermo-mechanical fatigue (TMF) and isothermal test results on standard laboratory specimens and specimens representing component features. The final verification will use results from rig testing on sub-elements of combustor and turbine casing geometry under component loading conditions.
Claimed innovative aspects of this proposal include:
- Advanced design methods based on 3D non-linear Finite Element component analyses;
- Extension of published models to represent non-isothermal and multiaxial loading conditions;
- Optimisation of non-linear FE methods to reduce run times and costs;
- TMF testing techniques for specimens with features;
- Definition of optimised specimen testing matrices for new combustor materials to reduce costs;
-Development of combustor and turbine casing rig tests capable of reproducing material loading conditions representative of engine service BE97-4034.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
- engineering and technology mechanical engineering vehicle engineering aerospace engineering aircraft
- natural sciences mathematics pure mathematics geometry
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Coordinator
DE24 8BJ Derby
United Kingdom
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