The advancement of high-temperature structural materials is crucial for the efficiency and performance of modern gas turbines, which are widely used in aviation and power generation. This paper explores the development and optimization of materials capable of withstanding extreme temperatures, mechanical stresses, and corrosive environments within turbine engines. The focus is on nickel-based superalloys, ceramic matrix composites (CMCs), and emerging materials such as high entropy alloys (HEAs) and refractory metals. Nickel-based superalloys are the current standard due to their excellent high-temperature strength and creep resistance, while CMCs offer potential for weight reduction and improved thermal efficiency. High entropy alloys, characterized by their unique multi-component systems, present promising properties including high strength and oxidation resistance at elevated temperatures. Additionally, advances in coating technologies and additive manufacturing are enhancing the durability and performance of these materials. The paper also discusses the challenges associated with material development, including the trade-off between strength and ductility, manufacturing complexities, and the need for long-term performance data. Future research directions are identified, focusing on the integration of computational materials science and advanced characterization techniques to accelerate the discovery and implementation of next-generation high-temperature materials. The successful development of these materials is essential for improving the efficiency and reducing the environmental impact of gas turbines.

This paper analyses the health and performance of 12-stage axial compressor of the TV3-117VM/VMA turboshaft operated in a desert environment. The results of the dimensional control of 4,800 worn blades are analysed to model the wear process. Operational experience and numerical simulations are used to assess the effectiveness of an Inlet Particle Separator. Numerical modal analysis is performed to generate the Campbell diagram of worn blades and identify resonant blade vibration which can lead to high cycle fatigue (HCF). It is shown that the gradual loss of the stall margin over time determines the serviceability limits of compressor blades. Recommendations setting out go / no-go criteria are made to maintenance and repair organisations.

Despite the serious threat of global warming caused by carbon emissions, commercial refrigeration systems that generate cooling are unable to adjust their usage time. Therefore, it is essential to enhance the energy efficiency of refrigeration systems themselves. Recently developed refrigeration systems offer improved energy consumption efficiency, as they utilize inverter-type outdoor units that can communicate with indoor units. However, traditional legacy refrigeration systems still suffer from poor energy efficiency because the existing indoor units cannot communicate with inverter-type outdoor units. Hence, this paper introduces a heuristic energy efficiency improvement algorithm for commercial refrigeration systems using legacy indoor units when an inverter-type outdoor unit is installed. In particular, to reduce the computational complexity of the process of selecting the optimal temperature difference and target low-pressure variables that can enhance energy efficiency, the algorithm employs the Monte Carlo method. Finally, the performance of the proposed heuristic energy efficiency improvement algorithm was evaluated in a laboratory environment to confirm its applicability.

Numerical optimization methods are widely used for designing turbomachinery components due to the cost and time savings they can provide. In the available literature, shape optimization of radial compressors is mainly focused on improving the impeller alone. However, it is a well-established knowledge that the volute plays a key role in the overall performance of the compressor. The aim of the present paper is to perform the adjoint-based optimization of a volute that is designed for the SRV2-O compressor. The CAD model is first created, using a parametrization of 33 design parameters. Then, a butterfly topology is applied to mesh the computational domain with a multi-block structured grid, and an elliptic smoothing procedure is then used to improve the quality of the fluid grid. A steady-state RANS CFD solver with Spalart-Allmaras turbulence model is used to solve the Navier-Stokes equations, and flow sensitivities are computed with an adjoint solver. The objective function consists in minimizing the loss coefficient of the volute. The optimization is performed to obtain an improved design with 14% losses reduction. Detailed flow and design analysis is carried out to highlight the loss reduction mechanisms followed by the optimizer. Finally, the compressor map of the full stage is compared between the baseline and the optimized volute through CFD simulations using a mixing plane interface. This research demonstrates the successful use of a gradient-based optimization technique to improve the volute of a radial compressor and opens the door towards optimizing simultaneously the wheel and the volute.

The growing importance of hydrogen as an energy carrier in a future decarbonized energy system has led to a surge in its production plans. However, the development of infrastructure for hydrogen delivery, particularly in the hard-to-abate sectors, remains a significant challenge. While the construction of new pipelines entails substantial investment, repurposing existing pipelines offers a cost-effective approach to jump-starting hydrogen networks. Many European countries are exploring the possibility of utilizing their current pipeline infrastructure for hydrogen transport. Yet, a critical aspect requiring extensive research is the expansion planning of these networks to accommodate increased capacity in the future. This study investigates the utilization of existing natural gas pipeline infrastructure for hydrogen transportation as a cost-saving measure. It explores two expansion strategies, namely pipeline looping and compression, for repurposing a segment of a 342 km x 36inch existing pipeline, from the Escravos – Lagos gas pipeline system (ELPS) in Nigeria, for hydrogen transport. Employing the Promax® process simulator tool, the study assesses compliance with the API RP 14E and ASME B31.12 standards for hydrogen and hydrogen-methane blends. Both expansion strategies demonstrate acceptable velocity and pressure drop characteristics for hydrogen blends of up to 40%. Additionally, the increase in hydrogen content leads to heightened compression power requirements until approximately 80% hydrogen in the blends for compression, and a corresponding extension in looping length until around 80% hydrogen in the blend for looping. Moreover, the compression option proves to be more economically viable for all investigated proportions of hydrogen blends for the PS1-PS5 segment of the Escravos – Lagos gas pipeline case study. The percentage price differentials between the two expansion strategies reach as high as 495% for a 20% hydrogen proportion in the blend. This study offers valuable insights into the technical and economic implications of repurposing existing natural gas infrastructure for hydrogen transportation.

In the following work, the assessment of the strength properties of the critical area of the rotor stage of the turbine jet engine was undertaken. This is the place of fixing the blade in the rotor disc. An important aspect of this issue are characteristic geometrical dimensions and operating factors e.g., change in rotor speed. In this paper, the assessment of the strength properties of the existing trapezoidal blade-disc connection was undertaken using parametric analysis considering FSI. Virtual models of the compressor rotor stage were developed, including parametric blade-disc connections and discrete models for FEM and CFD analyses. In the parametric analysis of the blade-disc connection, one-way fluid-structure coupling was used. The parametric analysis was aimed at assessing selected geometric parameters in terms of their impact on the maximum reduced stresses in the blade root. It was examined how the adopted value of the friction coefficient influences the maximum reduced stresses in the rotor stage of the compressor.

Micro turbojets are used for propelling radio-controlled aircraft, aerial targets and personal air vehicles. When compared to full-scale engines, they are characterized by relatively low efficiency and durability. In this context, the degraded performance of gas path components could lead to an unacceptable reduction in the overall engine performance. In this work, a data-driven model based on a conventional Artificial Neural Network (ANN) and an extreme learning machine (ELM) was used for estimating the performance degradation of the micro turbojet. The training datasets containing the performance data of the engine with degraded components were generated using the validated GSP model and the Monte Carlo approach. In particular, compressor and turbine performance degradation were simulated for three different flight regimes. It was confirmed that component degradation had a similar impact in flight than at sea level. Finally, the datasets were used in the training and testing process of the ELM algorithm with four different input vectors. Two vectors had an extensive number of virtual sensors, and the other two were reduced to just fuel flow and Exhaust Gas Temperature. Even with the small number of sensors, the high prediction accuracy of ELM was maintained for takeoff and cruise but was slightly worse for variable flight conditions.

Air conditioning system of electric vehicles has new change as the internal combustion engine is being replaced with electrified AC motor. With large amount of batteries installed at the bottom of frame, the conventional compressor which is belt-driven can be removed and another AC motor can play the role for air conditioning in electric vehicles. From this change, the system efficiency would be improved since it is possible to control the electrified compressor independently from traction system in contrast with the belt-driven compressor. As a result, by applying the electrified compressor for air conditioning system, the whole system can achieve better efficiency and longer driving distance, which is most important in electric vehicles. In this paper, 3-phase interior permanent magnet synchronous motor (IPMSM) was designed using lumped-parameter model and finite element method.

The ratio between blade height and chord, named aspect ratio (AR), plays an important role in compressor aerodynamic design. Once selected, it influences stage performance, blade losses, and the stage stability margin. The choice of the design AR involves both aerodynamic and mechanical considerations, and a reasonable aim is frequently to achieve a desired operating range while maximizing efficiency. For a fixed set of aerodynamic and geometric parameters there will be an optimal choice in AR that achieves a maximum efficiency. However, for a state-of-the-art aero-engine design optimality means multi-objective optimality, that is reaching the highest possible efficiency for a number of operating points while achieving a sufficient stability margin. To this end, the influence of the AR on the performance of the first rotor row of a multistage multi-objective high-speed compressor design is analyzed. A careful setup of the high-speed aerodynamic design problem allows the effect of the AR to be isolated. Close to the optimal AR, only a modest efficiency variation is observed, but a considerable change in compressor stability margin (SM) is noted. Decreasing the AR allows for an increasing efficiency, but at the expense of a reduced surge margin. This allows the designer to trade efficiency for stability. Increasing the AR, however, is shown to reduce both surge margin and efficiency, hence a distinct optimality in stability is observed for the analyzed rotor blade row. In this work, the optimality in surge margin with respect to AR is observed whereas a close to optimal efficiency. The predicted range from AR=1.10 to AR=1.64, is only indicative, considering that the definition of a multi-objective optimality requires balancing efficiency and surge margin and that the choice of balancing these two criteria requires making a design choice along a pareto optimal front.

A turbomachinery is essential part in the power generation cycle. But, it is main noise source to annoy workers and users and to make environmental problem. Thus it is important to reduce this noise for operating the power generation cycle. This noise is created by flow instability on rotor blade trailing edge. An airfoil that becomes a section of a rotor blade of a rotating machine is manufactured as a blunt trailing edge (TE) with a round or flatback shape rather than the ideal sharp TE shape for the purposes of producibility and durability. This increases the tonal noise and flow-induced vibration at low frequency owing to vortex shedding behind TE when compared with a sharp TE. In order to overcome this problem, this study investigates the oblique TE shape using numerical simulation. In order to do so, the flow was simulated using large eddy simulation (LES) and the noise was analysed by acoustic analogy coupled with LES result. Once the simulation results were verified using the flatback airfoil measurements of Sandia National Laboratories, numerical prediction was performed for airfoils modified to have oblique trailing edge angles of 60°, 45°, and 30° to analyse the flow and noise characteristics. From the simulation results for an airfoil having an oblique TE, it could be seen that the vortex shedding frequency moves in accordance with the oblique angle and that the vortex shedding noise characteristics change according to this angle when compared to the flatback TE airfoil. Therefore, it is considered that modifying the flatback TE airfoil to have an appropriate oblique angle can reduce noise and change the tonal frequency to a bandwidth that is suitable for mechanical systems.

A novel compressible real gas 1D finite volume thermofluid network modelling methodology is proposed that can be applied in the analysis of supercritical CO₂ (sCO2) power cycles. It is applied to simulate centrifugal compressor performance via a mean line approach that directly solves the mass, energy, and momentum balance equations for the discretized flow channels within the machine along with the associated loss models, component characteristics, and applicable compressible real gas equation of state. This can be integrated seamlessly with the rest of the power cycle components like pipes, valves, heat exchangers, etc., thereby eliminating the need for static performance maps and the associated difficulties to ensure similarity over the whole range of operation. This direct simulation of the internal flows also makes it possible to do integrated cycle design optimization that includes the geometry of the compressors, and to simulate fast transients for dynamic analysis. The methodology was applied to simulate well-documented air and sCO2 centrifugal compressors and compared the generated results with that of conventional thermofluid network incompressible and compressible ideal gas approaches. The results indicate that the proposed compressible real gas approach can capture the stagnation pressure changes and isentropic efficiencies with good accuracy for both cases over the whole range of mass flow rates and shaft rotational speeds. In contrast, the conventional thermofluid network incompressible and compressible ideal gas approaches are only applicable in selected regions of the fluid property regime and suffer from discretization errors and inappropriate treatment of the relationship between stagnation and static pressures. Furthermore, comparative analyses between the newly proposed approach and the traditional mechanical energy balance method are performed, showing that the latter approach needs to be discretized more finely through the compression process to correctly capture the polytropic compression path shape, whereas the former more accurately captures the stagnation pressure changes through the analyzed compressors with only a single increment per compressor component.

The work presents the results of numerical fatigue analysis of a turbine engine compressor blade, taking into account the values of initial stresses resulting from surface treatment - shot-peening. The values of the residual stresses were estimated experimentally using X-ray diffraction. The paper specifies the values of the residual stresses on both sides of the blade and their reduction due to the cutting through the blade - relaxation. The obtained values of the residual stresses were used as initial stresses in the numerical fatigue analysis of the damaged compressor blade, which is subjected to resonant vibrations of known amplitude. Numerical fatigue ε-N life analysis was based on the several fatigue material models: Manson’s, Mitchell’s, Baumel-Seeger’s, Muralidharan-Manson’s, Ong’s, Roessle-Fatemi’s and Median’s, and also on the three models of cyclic hardening: Manson’s, Xianxin’s, and Fatemi’s. Because of this approach, it was possible to determine the relationship between the selection of the fatigue material ε-N model and the cyclic hardening model on the results of the numerical fatigue analysis. Additionally, the calculated results were compared with the results of experimental research, which allowed for a substantive evaluation of the obtained results. These results are of great scientific and practical importance. The problem of determining the fatigue life of blades with defects operating under resonance vibrations is one of the original tasks in the field of fracture mechanics and experimental mechanics. The results obtained are of great importance in the aviation industry and can be used during engine maintenance and inspections to assess the suitability of blades with defects in terms of the needs of further work. This aspect of engineering maintenance is of great importance from the aircraft safety point of view.

Many probability-based uncertainty quantification (UQ) schemes require a large amount of sampled data to build credible probability density function (PDF) models for uncertain parameters. Unfortunately, the data collected in compressor blades of aero-engine are mostly limited due to expensive and time-consuming tests. In this paper, we develop a preconditioner-based data-driven polynomial chaos (PDDPC) method that can efficiently deal with uncertainty propagation of limited sampled data. The calculation accuracy of PDDPC method is closely related to the sample size of collected data. Therefore, the influence of sample size on PDDPC method is investigated using a nonlinear test function. Subsequently, we consider the real manufacturing errors of stagger angle for compressor blades. Under three different operating conditions, PDDPC method is applied to investigate the effect of stagger angle error on UQ results of multiple aerodynamic parameters of a two-dimensional compressor blade. The results show that as the sample size of measured data increases, UQ results of aerodynamic performance obtained by PDDPC method gradually converge. There exists a critical sample size that ensures accurate UQ analysis of compressor blades. The probability information contained in the machining error data is analyzed through Kullback-Leibler divergence, and the critical sample size is determined. The research results can make a valuable reference for the fast and cheap UQ analysis of compressor blades in practical engineering.

In this study, the on-going research into the improvement of micro-gas turbine propulsion system performance and the suitability for application as propulsion systems for small tactical UAVs (<600 kg) is investigated. The study is focused around the concept of converting existing micro turbojet engines to turbofan with the use of a continuously variable gearbox, thus maintaining a single spool configuration and relative design simplicity. This is an effort to reduce the initial engine development cost, whilst improving propulsive performance. The BMT 120 KS micro turbojet engine is selected for performance evaluation of the conversion process using gas turbine performance software, GasTurb13. The preliminary design of a matched low-pressure compressor (LPC) for the proposed engine is then performed using meanline calculation methods. According to the analysis carried out, an improvement in the converted micro gas turbine engine performance in terms of thrust and specific fuel consumption is achieved. Furthermore, with the introduction of a CVT gearbox, fan speed operation may be adjusted independently of the core, allowing increased thrust generation or better fuel consumption. Therefore, enabling a wider gamut of operating conditions and enhances the performance and scope of tactical UAV.

The development of new turbomachinery designs requires numerous time-consuming and computationally intensive computational fluid dynamics (CFD) calculations. However, most of the generated high spatial resolution data remains unused at later development steps. That is also the case with automated optimization processes that use only a few integral values to determine objectives and constraints. Therefore the development of a data-driven AI model was initiated to ensure the potential of further use of the CFD data which is also used to train the AI model. The presented method subsequently provides a fast approximation of the 3D flow for new designs. In this paper, the structure of the developed AI model is presented and the approximation quality is analysed using a complex, state-of-the-art compressor test case. It is shown that the AI model can reproduce many characteristics of the 3D flow of new designs, and performance measures such as efficiency can be derived from these flow predictions. In addition, the complex test case revealed that greater design variation reduces the AI approximation quality which can lead to undesirable exploratory behaviour in an optimisation setup. Overall, the test case has shown promising results and has provided hints for further improvements of the AI model.

Non-neural Machine Learning (ML) and Deep Learning (DL) are used to predict system failures in industrial maintenance. However, only a few studies have assessed the effect of varying the amount of past data used to make a prediction and the extension in the future of the forecast. This study evaluates the impact of the size of the reading window and of the prediction window on the performances of models trained to forecast failures in three data sets of (1) an industrial wrapping machine working in discrete sessions, (2) an industrial blood refrigerator working continuously and (3) a nitrogen generator working continuously. A binary classification task assigns the positive label to the prediction window based on the probability of a failure to occur in such an interval. Six algorithms (logistic regression, random forest, support vector machine, LSTM, ConvLSTM and Transformers) are compared using multivariate time series. The dimension of the prediction windows plays a crucial role and the results highlight the effectiveness of DL approaches in classifying data with diverse time-dependent patterns preceding a failure and the effectiveness of ML approaches in classifying similar and repetitive patterns preceding a failure.

Complex blade responses such as a rotating stall or simultaneous resonances are common in modern engines and their observation can be a challenge even for state-of-the-art tip-timing systems and trained operators. This paper analyses forced vibrations of axial compressor blades, measured during the bench tests of the SO-3 turbojet. In relation to earlier studies conducted in ITWL with a small number of sensors, a multichannel tip-timing system let us observe simultaneous responses or higher-order modes. To find possible symptoms of a failure, blade responses in a healthy and unhealthy engine configuration with an inlet blocker were studied. The used analysis methods covered all-blade spectrum and the circumferential fitting of blade deflections to the harmonic oscillator model. The proposed modal solver can track the vibration frequency and adjust the engine order on the fly. That way, synchronous and asynchronous vibrations are observed and analysed together with an extended variant of least squares. The proposed approach helps to avoid common mistakes and saves a lot of work related to configuring the conventional solver.

In this study, an optimization of the first blade in new test rig presented. Blade tuning is conducted using 3D geometrical parameters. Sweep and dihedral play an essential role in this study. Compressor characteristics and blades vibrational behavior are the main objective of the evaluation. Here, the attachments are designed to isolate blade dynamics from Disk. So, the Vibrational behaviors of the one's blade are tuned based on the self-excited and forced vibration phenomenon. Using a semi analytical MATLAB code instability conditions are satisfied. The code takes advantages of whitehead and force response theory to predict classically and stall flutter speeds. Beside, Forced vibrations instability is controlled using a theory presented by Campbell. Aerodynamics of new blade geometry determined using multistage simulations Computational fluid dynamics (CFD) software. Numerical results show increasing performance near the surge line and working interval along with increasing mass flow.

BACKGROUND: Manufacturing costs, along with operational performance, are among the major factors determining the selection of the propulsion system for unmanned aerial vehicles (UAVs), especially for aerial targets and cruise missiles. OBJECTIVES: In this paper, the design requirements and operating parameters of small turbofan engines for single-use and reusable UAVs are analysed to introduce alternative materials and technologies for manufacturing their compressor blades, such as sintered titanium, a new generation of aluminium and an alloy based on titanium aluminides. METHODS: To assess the influence of severe plastic deformation (SPD) on the hardening efficiency of the proposed materials, the alloys in the coarse-grained and submicrocrystalline states were studied. Changes in physical and mechanical properties of materials were taken into account. The thermodynamic analysis of the compressor was performed in a finite element analysis system (ANSYS) to determine the impact of gas pressure and temperature on the aerodynamic surfaces of compressor blades of all stages. RESULTS: Based on thermal and structural analysis, the stress and temperature maps on compressor blades and vanes were obtained, taking into account the physical and mechanical properties of advanced materials and technologies of their processing. The safety factors of the components were established based on the assessment of their stress-strength reliability. Thanks to nomograms, the possibility of using the new materials and the technologies was confirmed in view of the permissible operating temperature and safety factors of blades. CONCLUSIONS: The proposed alternative materials and production technologies for the compressor blades and vanes meet the design requirements of the turbofan at lower manufacturing costs.

This study investigates the effect of different variables in the optimization of a hybrid air charging systems for marine diesel engines, exploring the potential for energy recovery and assistance using electric machines. The optimization parameters include turbine speed, compressor power, start of injection, turbomachine size, and valve timing. At low engine speeds, the larger improvements come from increasing compressor power, which increases air-to-fuel ratio compared with the baseline turbocharging. As free-floating turbocharged engines are known to have low air-to-fuel ratio at low engine speeds, the relative improvement of the hybrid architecture is large at low engine speeds, being near to 10% less BSFC. At high engine speeds, the largest influence is marked by the SOI, an early injection obtains a faster combustion, which improves gross efficiency. However, the relative improvement compared with baseline turbocharger is less than 1% at high engine speeds. Due to the distribution of relative improvement of BSFC, this architecture has a deeper impact on fuel consumption in vessel operating cycles that focus on low engine speeds and loads, such as those of tugboats.