High Temperature Additive Architectures for 65% Efficiency DE-FE0031611
Chris Porter, PI Sharon Swede, PM Joe Weber, PM UTSR Project Review Meeting Orlando, FL November 6, 2019
High Temperature Additive Architectures for 65% Efficiency - - PowerPoint PPT Presentation
High Temperature Additive Architectures for 65% Efficiency DE-FE0031611 Chris Porter, PI Sharon Swede, PM Joe Weber, PM UTSR Project Review Meeting Orlando, FL November 6, 2019 This material is based upon work supported by the Department of
Chris Porter, PI Sharon Swede, PM Joe Weber, PM UTSR Project Review Meeting Orlando, FL November 6, 2019
This material is based upon work supported by the Department of Energy under Award Number DE-FE0031611
This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.
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Overall Objective
Develop a feasible Conceptual Design for Advanced Additive turbine inlet components that enable 65% CC efficiency through analytical methods and feature print trials.
Technical Approach
Phase I – Discovery
Coupon Print Trials.
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Performance
constraints
Speed to Market
Cost
Processing sciences Alloys Design
Improving state-of-the-art
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Additive
Ceramics
Process optimization
Merging design and manufacturing technology to deliver better products
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See insert on right 1st Stage Turbine Vane (Nozzle) 1st Stage Shroud 1st Stage Turbine Blade 2nd Stage Turbine Vane Transition Piece Combustion Liner
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Component we are focusing on in this project
Advanced Wall Architectures & Cooling Opportunities Advanced Training Edge Opportunities
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Surface/External Film Cooling Internal Cooling Flow Circuit
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Design Philosophy
Output/Performance.
while maintaining part life.
Design Challenges
regions to cool hotter areas on the Nozzle
Conceptual Design & Feasibility Additive Modalities & Materials
Strength & Oxidation Resistance 3D Printing Challenge
“Mature” 3D Experience Current 3D materials Advanced GTs
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Advanced Film Shapes Advanced H-Bumps Near-wall Microchannels Advanced Cooling Airfoil Compartmentalization & Impingement Reuse Axial Film Flow for Leading Edge Recirculating Trailing Edge
Program focus will be on high-temperature alloys, and additive modalities that enable their use
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Direct Metal Laser Melting (DMLM) Binder Jetting Fused Deposition Modeling (FDM)
Additive Modality Advantages Limitations
DMLM
Binder Jet
State” Fragility And Smaller Powder Particle Size
FDM
Each Modality Presents Opportunities And Challenges When Producing Complex Geometries
November 11, 2019 13 Pinned Wall Trials Round Cooling Holes Walls With Constant Spacing and variable thickness Ranges
Artifact Coupons Create Relatively Fast And Lower Cost Learning Of Modality Capabilities And Challenges
Round Serpentine and Elliptical Serpentine Channels
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Artifact Coupon Print Trials
representative of the advanced airfoil design.
be achieved without significant risk in production scale-up.
Binder Jet Trials FDM Trials Wall thickness Coupon Pinned wall coupon
Binder Jet DMLM
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Challenges
Areas. There is line of sight to producing complex features in Binder Jet. Going forward Further refinement to demonstrate dimensional quality, high yield and powder removal capability. Challenges
DMLM is favorable for producing full nozzles with complex cooling geometries. Going forward Part geometry and build orientation will be defined to minimize or eliminate strain age cracks.
FDM
Challenges
Areas. The least favorable option for producing Nozzles with complex cooling geometries. Going forward Will not be pursuing FDM for complex geometries at this time.
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Technology Gaps 1) Cooling Technology
features needed.
2) Wall Architecture Technology Bench Testing
assumptions and design benefits. 3) Additive Material Properties. (analogous to Cast properties vs Forged properties)
High Temperature Jet Thermal Shock Testing Rig GER / GEP Film Cooling Test Rig
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The road to 65% CC efficiency is challenging Additive Manufacturing is a paradigm shift in design for manufacturing. Early Career Engineers are the experts in additive manufacturing and design. In this program GE….
DMLM and Binder Jet are being pursued for further development on complex turbine components. .