Part One: Initial Report

Ernest Adewoyin - 5389209

M11EKM Advanced Manufacturing Processes and Materials 1312JANMAY

(18.5/40)

Coventry University 20/2/2014

Part One: Initial Report 2014

Notation
Symbol / Abbreviation HPC LPC A L m CSA S w t I E F C CES M y K1c Meaning High Pressure Compressor Low Pressure Compressor Area Length Density Mass Cross-Sectional Area Stiffness Width Thickness Second Moment of Area Youngs Modulus Force Elastic Deflection Arbitrary Constant Cambridge Engineering Selector Bending Moment Stress at distance y from the neutral axis of the beam distance Fracture Toughness Units (if applicable) unless otherwise stated m2 m kgm-3 kg m2 Nm-1 m m m4 Nm-2 N m

Nm-2 m Pa.m0.5

Introduction should be about component

This report aims to demonstrate the interactions between design requirements for a component and the materials and manufacturing route selection. It would be scrutinizing the Gas turbine compressor blade (high pressure compressor) from an Aerospace Engineering point of view.

Contents content should be before the introduction

Notation ..................................................................................................................................... 1 Introduction ................................................................................................................................ 1 Contents .................................................................................................................................... 1 Section 1 .................................................................................................................................... 2 Section 2 .................................................................................................................................... 3 Titanium Alloys ....................................................................................................................... 6 Bibliography ............................................................................................................................... 7

Part One: Initial Report 2014

Section 1 4/5
The Gas turbine compressor blade is one that can be found in a Gas Turbine Engine from an Aerospace Engineering perspective; this includes a Jet Engine for Turbojet airplanes such as the DC-8 airliner and the F-14 fighter plane. The Jet Engine has been in principle since 1935 developed by Sir Frank Whittle (The Wonder Jet, 1950).

Figure 1: Basic components of a turbine engine (Free Online Private Pilot Ground School, 2006)

Considering Figure 1 as an applicable example; the gas turbine blades functions in the high pressure compressor (HPC) chamber of the cold section of the whole turbine engine. In the system of Figure 1, air is sucked in from the air-inlets due to the pressure difference across the turbine engine. From the inlet-nozzle to the end of the compressor chamber, the air transits to the combustion chamber through an area reduction in the size of the compressor-chamber as seen in Figure 1. The function of the gas turbine HPC blades is to accelerate the compressed air over the decreasing area of the nozzle into the combustion chamber. Fuel is added in the combustion chamber and the air is ignited. This is passed out of the exhaust chamber at a higher velocity than when it came in. Consequently, this propels the system in the forward direction. Discussion on materials requirements is very limited -- 4/10 In this day and age, engineering and manufacturing companies are inclined to produce materials that are very functional yet of very low densities; this also applies to Figure 1. Typically, the Gas turbine HPC blade experiences over 16000kg of centrifugal force in it revolutions and moves compressed air approximately at 447.04ms-1. This means that the material of the turbine blade needs to be strong enough to avoid failure even though centrifugal load acting on it but it is a cyclic and need materials with high fatigue strength. The compressed air could also reach temperatures as high as 700C; this means that the material of the compressor blades needs to be tough enough to absorb and withstand (heat) energy should have minimum service temperature of 700C. The whole blisk is a working section of the turbine blades as it includes the rotor-discs and the arrayed turbine blades mounted on it. Industrially, a full ship-set of HPC blades can cost between 100,000 to 200,000 (Ackert, n.d.). Upon failure, the HPC blades need to be mounted on the rotor-disc in such a way that it can be replaced.

Part One: Initial Report 2014

Assuming that the Low Pressure Compressor (LPC) blade is made out of the same material that the HPC blade is made out from, a typical LPC fan blade has a service life cycle of 17600 total life cycles (Nepal Airline Corporation, 2013). Pragmatically, this is equivalent to an average of 1 to 2 years of service life.

Section 2 6/10
The function of the blade is likened to that of a beam. This is because the HPC blade itself is curved in shape and it drives volumes of high-temperature air across its surface. This means that during operation, it is simultaneously expanding in length and bending in shape due to heat and centrifugal force acting on the material.

Figure 2: Sample of a HPC Blade (TTL, 2014)

Figure 3: Simple Beam Model (Swanson, 2014)

The shape of the object is a non-circular prismatic, flat sheet and 3-D solid. The materials selection must be limited for poor thermal conductors. The objective is to minimize its mass, m using The constraint parameter is the stiffness, S of the blade. This is because the blade has to be stiff enough to resist bending under high pressure and temperature. The free variable is the thickness of the blade and the materials choice. Assuming the blade is a rectangular beam as shown in figure 3 (in similitude to the HPC blade). The material needs to be tough to withstand all sorts of energies such a heat. Also,

[ Substitute for I in (2) and (3).. ( Substitute (4) into (1).. ( ) ( ) )

Part One: Initial Report 2014

This means that in order or to minimize the mass, ( ) has to be maximized. To find the gradient; ( )

Therefore the gradient is equal to 3. Should have included few more material

Chart 1: CES Software Level 2 Zoomed-In Logarithmic Graph of Youngs Modulus VS Density

Considering the materials above the gradient line and starting from the highest, the top 3 materials with the highest ( ) ratio are Titanium Alloys, Commercially Pure Titanium and Metal Foam. Chart 1 indicates that Titanium Alloys is the toughest. stiffer The material also needs to be strong to physically withstand the accelerating air and centrifugal forces. Using the Generic Bending equation

Part One: Initial Report 2014

( Substitute (6) into (1)..

This means that in order to minimize the mass, ( ) needs to be maximized. To find the gradient; ( )

Therefore, the gradient is equal to 2.

1000

Titanium alloys Commercially pure titanium

Yield strength (elastic limit) (MPa)

100

10

Metal foam

500

Density (kg/m^3)

1000

2000

5000

Chart 2: CES Software Level 2 Zoomed-In Logarithmic Graph of Yield Strength VS Density

Part One: Initial Report 2014

Considering the materials above the gradient line and starting from the highest, the top 3 materials with the highest ( ) ratio are Titanium Alloys, Commercially Pure Titanium and Metal Foam. Chart 2 indicates that Titanium Alloy is the strongest. The material also needs a high specific fatigue strength to resist vibrations and frequencies that may rupture the material; and a high specific fracture toughness to resist the continuities or cracks as much as possible. This means that a graph of VS is needed.
Titanium alloys
0.1

Fatigue strength at 10^7 cycles / Density

Commercially pure titanium

Stainless steel
0.01

0.001

0.002

Fracture toughness/Density

0.005

0.01

0.02

Chart 3: CES Software Level 2 Zoomed-In Logarithmic Graph of

VS

Assuming a gradient of 1 and in order of highest; Chart 3 indicates that top 3 materials with high ( ) ratio are Titanium Alloys, Stainless Steel and Commercially Pure Titanium.

Although the CES Software is an excellent aid in achieving material-selection and processes but it is ultimately dependent on the individual making a human-judgment based on many other attributes that the material should possess to achieve the overall desired purpose.

Titanium Alloys
Titanium Alloys have passed all three tests required to select a material for the HPC blade. Industrially, Titanium Alloys are commonly used for HPC blades. They are very expensive but due to their functionality, price is less of a limiting factor. Titanium has a relatively low density of 4.6e3kg/m3. It has a high youngs modulus of up to 120GPa and a Yield Strength (elastic limit) of around 1000MPa. Titanium has a Maximum Service Temperature of up to 500C which seems like a disadvantage but it is balanced out with the fact that it is a very poor thermal

Part One: Initial Report 2014

conductor. It melts close to 1700C and it has a lot of alloys such as Ti-8Al-1Mo-1V, Ti-8Al-4V and Ti-5Al-2.5Sn etc. Their numbers are the percentage compositions of the different elements in its alloys. Due to its extreme toughness, it is difficult to machine and this means that cooling holes are difficult to achieve on the HPC blade I dont think there is any cooling system in the compressor. It is almost impossible to cast like cast iron and since lead oxide was banned in paints around the 1970s, titanium dioxides have been in high demand to as a replacement. A very large scale production of Titanium would greatly affect the natural order of earths environment. However, Titanium is relatively light and strong. It has a very long shelf-life; this means that parts for the HPC blade can be stored in wait for replacement. Finally, it is extremely resistant to corrosion and wear as it acts in such a way to repair and protect itself. With the absence of any other material to outweigh the effectiveness of Titanium, I avoid use of first person would select Titanium Alloys to be the Material that the HPC blade is made out of.

Bibliography

references

Ackert, S., n.d. Engine Maintenance Concepts for Financiers, s.l.: Aircraft Monitor. Free Online Private Pilot Ground School, 2006. Turbine Engines. [Online] Available at: http://www.free-online-private-pilot-ground-school.com/turbine-engines.html [Accessed 20 Febraury 2014]. Nepal Airline Corporation, 2013. NEPAL AIRLINES CORPORATION ENGINEERING DEPARTMENT TRIBHUVAN INTERNATIONAL AIRPORT KATHMANDU, NEPAL, Nepal: Nepal Airlines Corporation. Swanson, P., 2014. Course: M11EKM - Advanced Manufacturing Processes and Materials 1314JANMAY. [Online] Available at: http://cumoodle.coventry.ac.uk/course/view.php?id=9946 [Accessed 21 February 2014]. The Wonder Jet. 1950. [Film] Directed by UK Crown. United Kingdom: C.O.I. FILM PRODUCTION. TTL, 2014. Adaptive Machining for Compressor and Turbine Aerofoils. [Online] Available at: http://www.ttl-solutions.com/aerofoils.html [Accessed 21 February 2014].

Report Structure 5.5/10 1. 2. 3. 4. Check the presentation improve technicality Improve referencing Discuss the Fig used