This paper presents an experimental and numerical investigation into film cooling performance over a flat plate. As previous studies have shown, the flow situation at the entry-side of the cooling hole shows a notable effect on film cooling performance. The present investigation takes this into account feeding the cooling holes from an internal cooling channel and not from a stagnant plenum. High resolution heat transfer coefficient and adiabatic film cooling effectiveness distributions received from transient liquid crystal experiments are presented. The Reynolds numbers of the hot gas channel and the coolant crossflow feeding the holes are varied. Furthermore, the effects of 45° angled ribs, introduced into the cooling channel, are investigated. The experiments are performed at constant blowing, momentum and pressure ratios. Numerical calculations of the adiabatic film cooling effectiveness for selected configurations using FLUENT are presented. Comparison reveals the influence of coolant channel Reynolds number and the introduced ribs on the cooling hole flow pattern leading to a changed film cooling performance.
Additive manufacturing and in particular Selective Laser Melting (SLM) are manufacturing technologies that can become a game changer for the production of future high performance hot gas path parts. SLM radically changes the design process giving unprecedented freedom of design and enabling a step change in part performance. Benefits are manifold, such as reduced cooling air consumption through more efficient cooling schemes, reduced emissions through better mixing in the combustion process and reduced cost through integrated part design. GE is already making use of SLM for its gas turbine components based on sound experience for new part production and reconditioning. The paper focuses on: a) Generic advantages of rapid manufacturing and design considerations for hot gas path parts b) Qualification of processes and additive manufacturing of engine ready parts c) SLM material considerations and properties validation d) Installation and validation in a heavy duty GT Additive Manufacturing (AM) of hot gas path components differs significantly from known process chains. All elements of this novel manufacturing route had to be established and validated. This starts with the selection of the powder alloy used for the SLM production and the determination of essential static and cyclic material properties. SLM specific design features and built-in functionality allow to simplify part assembly and to shortcut manufacturing steps. In addition, the post-SLM machining steps for engine ready parts will be described. As SLM is a novel manufacturing route, complementary quality tools are required to ensure part integrity. Powerful nondestructive methods, like 3D scanning and X-ray computer tomography have been used for that purpose. GE’s engine validation of SLM made parts in a heavy duty GT was done with selected hot gas path components in a rainbow arrangement including turbine blades with SLM tip caps. Although SLM has major differences to conventional manufacturing the various challenges from design to engine ready parts have been successfully mastered. This has been confirmed after the completion of the test campaign in 2015. All disassembled SLM components were found in excellent condition. Subsequent assessments of the SLM parts including metallurgical investigations have confirmed the good part condition.
The degradation of gas turbine parts due to aging leads to changes in airfoil shape and often causes performance loss. Although the degradation mechanisms and their effects on performance are understood in general (e.g. it is well known that fouling of compressor airfoils reduces mass flow and efficiency), the first quantitative relationships between specific types of part degradation and performance characteristics have only recently been published. In this paper the degradation of turbine blades with aft-loaded airfoils is considered. The typical deviations of shape were identified based on field experience. The effects of these deviations on turbine performance were assessed using different calculation methods, including 3D Navier-Stokes calculations and methods based on empirical correlations. The effect of blades-length reduction, chord-length reduction, changes in trailing-edge thickness and shape, and variation of stagger angle were analysed. The analysis showed that for aft-loaded airfoils without shrouds, the major influence on turbine performance is the degradation of radial clearances. A simplified engineering procedure allowing estimation of turbine performance loss due to degradation has been developed. This paper demonstrates how this simplified procedure, can be applied to the estimation of turbine recovery potential during a typical engine overhaul.
Increased availability, reliability and performance combined with reduced maintenance costs are key factors for the success of gas turbine users. Alstom reconditioning answers to this market demand by providing advanced and competitive repair techniques and an increasing broad reconditioning portfolio to its customers. This paper focuses on the reconditioning of film cooled SX components used in the GT24 and GT26 fleet and the latest enabling technologies. The general reconditioning strategy is based on a thorough analysis of the accumulated field experience with SX parts and a controlled, step-wise introduction of new techniques. Taking advantage of the broad interdisciplinary OEM product and design know-how, as well as Alstom’s rich engineering experience in advanced reconditioning, state of the art reconditioning processes have been developed for different damage scenarios for components. This would include the most technically challenging SX “heavy” scope reconditioning. This paper gives an overview about the reconditioning sequence for SX components and some of its key process steps. As an example, the crack braze repair process is described in detail and several novel SX welding techniques for crack repairs, blade tip and temperature controlled leading edge wall thickness restoration are shown. This covers different processes such as TIG welding or laser metal forming (LMF) of SX components. During the last few years, highly automated production solutions and innovative production tools have been implemented, which enable high capacity and consistently high quality of reconditioning. After their successful validation and a limited phase of monitored production, these techniques are applied on rotating and stationary SX turbine parts. Validation criteria and the experience gained during the first years of commercial production and operation in the field will be presented.
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