Design, simulation, and validation of additively manufactured high-temperature combustion chambers for micro gas turbines

Adamou, Adamos; Turner, J. W. G.; Costall, Aaron; Jones, Andy; Copeland, Colin

doi:10.1016/j.enconman.2021.114805

Cited by 19 publications

(8 citation statements)

References 26 publications

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Section: Resultsmentioning

confidence: 99%

“…Since it was not possible to measure the air mass flow that was entering the primary zone, the equivalence ratios were taken from the CFD primary zone air mass flow rate predictions, which were previously determined using full-scale 3D reacting CFD in the authors' previous publication. 41 The geometries tested had three variables: the type of swirler used, the type of liner and the number of dilution holes. The baseline swirler refers that depicted in Figure 1, while the one-and three-row lattice swirlers reference the alterations to the baseline shown in Figure 2.…”

Section: Geometry Comparisons At Variable Inlet Temperature and Const...mentioning

confidence: 99%

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Experimental performance and emissions of additively manufactured high-temperature combustion chambers for micro-gas turbines

Adamou

Costall

Turner

et al. 2022

International Journal of Engine Research

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To date, 59 countries, representing 54% of global greenhouse gas emissions have made pledges for net-zero emissions targets within this century. This will require cleaner and more efficient sources of energy which is driving research into small-scale engines and auxiliary power units for hybrid vehicles and stationary power generation. A suitable candidate for such applications is the micro gas turbine due to its high-power density, reliability and low emissions. Further development of such engines is required though due to their increasing parasitic energy losses relative to net power output as size decreases. Additive manufacturing offers the design freedom to not only increase efficiencies but to also reduce emissions when applied to the various components of micro gas turbines. This article reports the effects of several additive manufacturing (AM) enabled design features for micro gas turbine combustion chambers via experimental testing of full-scale parts. The main objective of the additively manufactured features is the reduction of exhaust emissions by improving the air-fuel mixture distribution and consequently ignition and combustion. Using additive manufacturing a novel conical radial swirl-stabilized tubular combustor with internal vane fuel injection was created as a baseline for the laboratory testing. Several other features, including augmented backside liner cooling surfaces, in-vane lattice structures for fuel mixing and upstream liner fuel injection rings were also generated to further the investigations into additively manufactured features and their effects on fuel mixing. Using multiple combinations of all these features, 10 geometries were generated and tested at a variety of operating conditions. Three inlet temperatures were tested (500°C, 600°C and 700°C) with varying fuel flow rates to investigate their operating limits at a constant inlet pressure of 4 bar absolute. Test results for the full range of equivalence ratios and operating conditions showed that the upstream liner fuel injection designs generated NOx, CO and THC emissions on par with the baseline but showed a reduction in the maximum and minimum operating ranges. This design, however, demonstrated the distinct advantage of being able to ignite at full air mass flow; this is not possible with the baseline designs and is also an added benefit to its main use which is the reduction of liner temperature. Overall, the test results underscore that designing combustion chambers for additive manufacturing can provide a myriad of benefits not only for micro gas turbines but also for other applications requiring high efficiency combustion chambers.

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Section: Resultsmentioning

confidence: 99%

Section: Geometry Comparisons At Variable Inlet Temperature and Const...mentioning

confidence: 99%

Experimental performance and emissions of additively manufactured high-temperature combustion chambers for micro-gas turbines

Adamou

Costall

Turner

et al. 2022

International Journal of Engine Research

Self Cite

View full text Add to dashboard Cite

show abstract

“…By changing the combination of various components, skins, internal channels and feed pipes, as well as developing a single multi-functional panel made of additives, it can achieve the required multi-functional combination. A micro gas turbine [105] is especially suitable for its high power density and reliability. Additive manufacturing provides a degree of design freedom, which can provide higher efficiency and lower emissions for micro gas turbine applications.…”

Section: Analysis Of Application Fieldsmentioning

confidence: 99%

Considerations for the Variable Density Lattice Structure of Additive Manufacturing: A Review

et al. 2022

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In recent decades, the additive manufacturing technology has made great progress in software and methods in various fields, and gradually explored in a deeper and broader manner. It has changed from the mature homogenized lattice type and model design to a non-uniform direction. It has also started to improve from the aspects of material innovation, additive manufacturing printing technology, etc., to change the additive manufacturing technology and control parameters in the manufacturing process, Furthermore, the model or part can be improved to have better mechanical properties, such as stiffness, strength and wear resistance, which provides an important research methodology for the better development of this direction. These aspects include the software used, the type of structural analysis, the software used and verification, as well as the methods applied in the study of variable density lattices and the application and verification of improved research methods. In addition, there are density design optimization, variable density lattice design and lattice geometric characteristics’ design in geometric topology optimization design. The expected design of the model or part at the design level has reached the ideal model or part, which provides both a framework and ideas for the future research direction of non-uniform lattice design and a broader field of application, and will promote the future research and development prospects of variable density lattices.

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“…are found. 5–10 In these systems, micro-size rotating disks form a major component. For providing enhanced efficiency and performance from thermodynamic considerations, these systems need to operate at extremely high speeds and at elevated temperatures under high transverse pressure of fluids.…”

Section: Introductionmentioning

confidence: 99%

Free vibration response of bidirectional functionally graded rotating micro-disk under mechanical and thermal loading

Pal

Das

2023

The Journal of Strain Analysis for Engineering Design

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The present work studies the free vibration response of functionally graded rotating micro-disks subjected to transverse pressure and thermal loading based on the modified couple stress theory. The disk material is considered to be functionally graded along the radial and thickness directions, and its properties are assumed to be temperature-dependent following the Touloukian model. The mathematical formulation is based on an energy functional involving the von Kármán type non-linearity, in which appropriate displacement derivatives and its conjugate stress measures are used to define the strain energy of the micro-disk. The minimum potential energy principle is employed to develop the governing equations for determining the deformed configuration of the micro-disk under combined centrifugal, pressure and thermal loading. Further, the governing equations for free vibratory motion of the micro-disk are derived following Hamilton’s principle and incorporating the tangent stiffness of the deformed micro-disk. The governing equations are discretized and solved employing the Ritz method. The mathematical model is successfully validated with different reduced problems available in the literature. The influence of rotational speed, transverse pressure, thermal loading, size-dependent thickness and volume fraction indices are investigated for a wide range of parametric values. Some illustrative mode shapes along with the contour have also been presented. The present study is first of its kind and the presented results would definitely serve as benchmarks for any further study in this field.

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Design, simulation, and validation of additively manufactured high-temperature combustion chambers for micro gas turbines

Cited by 19 publications

References 26 publications

Experimental performance and emissions of additively manufactured high-temperature combustion chambers for micro-gas turbines

Experimental performance and emissions of additively manufactured high-temperature combustion chambers for micro-gas turbines

Considerations for the Variable Density Lattice Structure of Additive Manufacturing: A Review

Free vibration response of bidirectional functionally graded rotating micro-disk under mechanical and thermal loading

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