Jet Engines

Jet Engines from JT8D to Trent 1000
During the last decades the jet engines went through significant improvements in terms of performance, efficiency, emissions and acoustics. The presentation will demonstrate various strategies of the engine manufacturers like GE, Pratt & Whitney and Rolls-Royce, their results and the ways how these results have been achieved. The author will break down the engine into the modules like compressor and the turbine and will provide the status of the art as well as the latest development in design and material science.
ETN Aviation GmbH Am Becketal 14 D-28755 Bremen www.etn-aerospace.com Dr. Ing. T. Valenta Manager Engineering tvalenta@etn-aerospace.com Dial +49 172 422 77 24
tvalenta@etn-aerospace.com
Content
1. Intro 1.1 Economy drives Technology 1.2 Engine Characteristics 2. Fan & Compressor 2.1 Fan Blade Development 2.2 Compressor Design (Fluid Dynamics, Sealing, Materials) 2.3 Stability program 3. Combustion 3.1 Design Changes 3.2 Low NOx Burner 3.3 CC Materials 4. Turbine 4.1 Turbine Design 4.2 Turbine Blades (Cooling, Coating, Sealing, Materials)
1. Intro 1.1 Economy drives Technology

Development is driven by customers = airline needs
NORDAM Hush Kit for JT8D 3 Mio USD cost / ea. 90ties
airline
OEM airplane
OEM engine
efficiency fuel cost thrust passenger volume emissions, acoustics penalties
competition politics supplier R&D OEM programs
1.2 Engine Characteristics

MAJOR PARAMETERS: * pressure ratio PR = p2/p1 * turbine inlet temperature TIT = T3 * thrust S = dm/dt . v mass flow, velocity engine size
TIT
4
PR
1 s
3m 2m 1m
JT8D
PW4
GE90
5
2. Fan & Compressor 2.1 Fan Blade Development
Shape Type Material
straight shrouded Ti 6-4 forged
swept shrouded Ti 6-4 forged
straight shroudless Ti hollow
swept shroudless
aerodynamics improve reduced shock losses
Ti hollow (PWA), composit (GE)
Bypass Ratio: 5 7 11 70ties: Rolls-Royce the first to introduce composite fan blades insolvency program due to composite failure (FOD became an issue) GE introduces GE90 wide cord composite fan blade with Ti-stiffened trailing edge
6
90ties:
British Design (RR)

3 spool engine HP, IP, LP LPT drives fan only
US Design (PWA, GE)

2 spool engine HP, LP LPT drives fan and LPC Geared fan (new generation)
2.2 Compressor Design

Focus only on axial compressor:
1990 RR Trent 600

15 stg. Triple spool compressor 8 stg. Intermediate pressure 6 stg. High pressure Pressure Ratio 35 : 1 Mass Airflow 130 kg/s Outlet Temperature 600C Thrust 68000 lbs
1960 GE CJ805
17 stg. Single spool compr. Pressure Ratio 13 : 1 Mass Airflow 55 kg/s Thrust 12000 lbs
Fluid Dynamics
1-D isentropic airflow Radial equilibrium known but not respected in design Stagger angle dependent on circumferential velocity with constant blade profile Neue allgemeine Theorie der mehrstufigen axialen Turbomaschine, W. Traupel 1942, ETH
2-D semi-empirical grid method Secondary flows respected by empirical correlations The prediction of the performance of an axial compressor stage, M. Casey 1988, Rolls-Royce
3-D Viscous Numerical Method (RANS) determines 3-D contour of the airfoil Advanced Compressor and Fan Systems David C. Wisler 1988, GE Ref. Navier Stokes Equations 1822
v + v v ) = p + v t
Nonlinear partial equation system. Numerical analysis only:
u E F G R S T + + + = + + t x y z x y z
LES Large Eddy Simulation
Tip Clearance Vortex Flow M. Casey 1990, Sulzer Turbosystems (ex RR)
10
Sealing
- Blade Tip Clearance Loss Rubber, Honeycomb, Abradable - Rotor Dovetail Leakage Fit, Sealant (Solid Lubricant MoS2, PTFE, Graphite, Cu based) - Stator Shroud Leakage Rubber, Honeycomb, Abradable, Brushseal
11
PWA design
Rubber in LPC (up to 200C)
Feltmetall in HPC (up to 600C) sintered Hastelloy X fibres
12
R-R design
MTU design
Abradable (Al12Si in IPC)
Brushseal (also used in PW4460 Phase III HPC stg. 15)
13
Materials
LPC, IPC: HPC: - Ti Al6V4 forging Ni-based alloy Inconel 718 forging (PWA) density 8.2 g/cm -TiAl precision cast is current R & D (GE, R-R) density 4.2 g/cm
Ti-alloy Ti-6Al-4V: - composition -hex: higher thermal resistance -cub: higher strength bimodal (coarse globular, lamellar)
Titan Aluminide TNB-V3, Ti-45Al-8Nb-0.2C-0.2B: lamellar, high strength C. high creep resistance, poor ductility B. fine grain, mixed mode
14
2.3 Stability Program

active surge/stall control Edward Greitzer, Sabri Deniz MIT smart pressure probes Georg Gyarmathy ETH
90ties: Swissair surge problem
15
PW4460 deterioration chart continous increase of TSFC
TO
Facts and Figures:

- TSFC after OVHL never as good as new engine - high surge risk if turbine overhauled and compressor in as-is condition
16
3. Combustion 3.1 Design Changes

- Can Type 9 10 cans in ring - Annular Type (various manufacturing technologies) - Double Annular Type (Low NOx)
PW 4000 Annular Type Liners forged and welded Twall = 1000C (TO) 860C (Cruise)
Air flow
114 kg/s (TO) 41 kg/s (Cruise) Fuel flow 2.51 kg/s (TO) 0.71 kg/s (Cruise)
Tay 620 Cannular Type 10 cans in ring
Trent 500 Annular Type 2 forgings, assy EB welded Cooling holes YAC laser drilled Dillution holes machined
17
Fuel Nozzle
Diffusion flame, no premix UP TO TODAY
JTD Fuel Nozzle dual fuel flow type
PW4 Fuel Nozzle swirler vanes
18
JT8D Fuel Nozzle Failure

Design: 9 cans in ring, problem can no. 7: AD due to Engine Fire Fuel Nozzle displaced and burned a hole into the can wall
nut critical area due critical area due to thermal shock to nut vibrations
thread crack
Root cause: TMF
prim sec fuel flow

tvalenta@etn-aerospace.com 19
Modification of JT8D Fuel Nozzle

A. EB welded ring-nut instead of threaded nut B. Notch effect eliminated due to smooth contour
B B
A
old configuration
A
new configuration
High stress area in EB welded region
20
3.2 Low NOx Burner

General formation of NO (Zeldovich, Arrhenius):
= c1 t NO N
time
L O
2
c 2 e T
temperature
DAC CFM56-5B
Single Annular Burner CFM56-5B
21
3.3 CC Materials
Base material: Ni-based alloy e.g. Hastelloy X Two layer thermal barrier coat: metallic bond, ceramics
0.25-0.40 mm 0.13-0.20 mm
ZrO2
NiCoCrAlY Hastelloy X
Y2O 3
22
4. Turbine 4.1 Turbine Design
Pratt & Whitney PW4 straight vanes turbine case cooling (compressor bleed-air)
Rolls-Royce Trent 500 bowed vanes 7 turbine stages
23
4.2 Turbine Blades

Ni-based alloy PC, DS, SX Convection, film cooling Ceramic coated
JT9Q Blade 70ties First SX, out of service due to clean cracking
PW4 Blade 90ties First and second SX-Generation
24
Cooling
Cooling flow equation:
& m = A
2 1
1 RTi
pi
2 2
po (1
[ ]
po pi
Cross-section CFM56-7 3 cooling flow sections
Cooling flow chart (wcorr corrected airflow)
cools leading edge and tip
cools trailing edge cools pressure side
25
Film Cooling Very efficient if properly working:
flow attached: high c
flow separated: low c

(e.g. due to in-service plugging)
c film 0.4 0.3 0.2 0.1 mc/t 0.05 0.10 0.15 convection
PWA T1 bulged on SS due to poor film cooling
26
Coating
High elasticity gradient (thermal growth) metal-ceramic EB-PVD columnar crystal growth allows coating to expand
27
Sealing
RR conventional design shrouded blades and honeycomb
PWA High-Tech design abrasive blade tip and abradable shroud
28
PWA design
Abrasive blade tip:
145 Y2O3 115 ZrO2 75 Y2O3 ZrO2 ZrO2
Abradable shroud segment:
Al2O3 40 CoCrAlY
SiC grits encapsulated cBN Blade Tip in a TiN diffusion barrier
ZrO2
CoCrAlY
Al 2O3
5 0
NiCrAlY PWA 263
NiCrAlY PWA 283
PWA 263 is 5 layer coating PWA 283 is graded coating maintained by 18 spray parameters tvalenta@etn-aerospace.com 29
Reason for introduction of improved abradable PWA 283:
Zirconia spalling after 2000 eng. hrs. Spalling causes engine performance loss of 1.8 % TSFC, EGT loss of 20C.
Two main reasons for spalling: 1. High elasticity gradient across substrate, bond and zirconia 2. Insufficient cooling against the airflow (see Position B)
NGV w c w u Segment B c u w Segment A
Position A Film Cooling
cn
cn
Position B Film Cooling
Blades
30
Latest development SumeGrid shows excellent thermal resistance (Sulzer Metco)

HoneyComb Mesh (Sume Grid) Zirconia
Substrate
Braze
Homogenous zirconia easy to apply
31
Materials
Material: Nickel-base alloys PC, EQ (DS), SX
Defects in single crystal blade
Defects in equiaxed blade
32
Metallography
polycrystalline structure (grain boundaries)
single crystal (gamma prime eutectica)
33
Precipitant Coarsening
gamma prime virgin
gamma prime after service
34

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Jet Engines from JT8D to Trent 1000

1. Intro 1.1 Economy drives Technology

efficiency fuel cost thrust passenger volume emissions, acoustics penalties

competition politics supplier R&D OEM programs

1.2 Engine Characteristics

2. Fan & Compressor 2.1 Fan Blade Development

Shape Type Material

straight shrouded Ti 6-4 forged

swept shrouded Ti 6-4 forged

straight shroudless Ti hollow

aerodynamics improve reduced shock losses

Ti hollow (PWA), composit (GE)

British Design (RR)

US Design (PWA, GE)

2.2 Compressor Design

1990 RR Trent 600

Nonlinear partial equation system. Numerical analysis only:

Rubber in LPC (up to 200C)

Feltmetall in HPC (up to 600C) sintered Hastelloy X fibres

Abradable (Al12Si in IPC)

Brushseal (also used in PW4460 Phase III HPC stg. 15)

2.3 Stability Program

90ties: Swissair surge problem

PW4460 deterioration chart continous increase of TSFC

Facts and Figures:

3. Combustion 3.1 Design Changes

Tay 620 Cannular Type 10 cans in ring

JTD Fuel Nozzle dual fuel flow type

PW4 Fuel Nozzle swirler vanes

JT8D Fuel Nozzle Failure

prim sec fuel flow

Modification of JT8D Fuel Nozzle

High stress area in EB welded region

3.2 Low NOx Burner

Single Annular Burner CFM56-5B

4. Turbine 4.1 Turbine Design

Rolls-Royce Trent 500 bowed vanes 7 turbine stages

4.2 Turbine Blades

PW4 Blade 90ties First and second SX-Generation

Cross-section CFM56-7 3 cooling flow sections

Cooling flow chart (wcorr corrected airflow)

cools leading edge and tip

cools trailing edge cools pressure side

Film Cooling Very efficient if properly working:

flow attached: high c

flow separated: low c

PWA T1 bulged on SS due to poor film cooling

RR conventional design shrouded blades and honeycomb

PWA High-Tech design abrasive blade tip and abradable shroud

Abradable shroud segment:

NiCrAlY PWA 263

NiCrAlY PWA 283

Reason for introduction of improved abradable PWA 283:

NGV w c w u Segment B c u w Segment A

Position A Film Cooling

Position B Film Cooling

Latest development SumeGrid shows excellent thermal resistance (Sulzer Metco)

Homogenous zirconia easy to apply

Defects in single crystal blade

Defects in equiaxed blade

polycrystalline structure (grain boundaries)

single crystal (gamma prime eutectica)