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.

Lubricated tribosystems such as main-shaft bearings in gas turbines have been successfully diagnosed by oil sampling for many years. In practice, the interpretation of wear debris analysis results can pose a challenge due to the intricate structure of power transmission systems and the varying degrees of sensitivity among test methods. In this work, oil samples acquired from the fleet of M601T turboprop engines were tested with optical emission spectrometry. Two-way analysis of variance (ANOVA) with interaction analysis and post hoc tests were carried out on measurement data from the whole fleet of the M-601T turboprop engines to study the impact of aluminum and zinc concentration on iron concentration. Finally, the developed model was used to evaluate the oil testing results for two specific engines of this type. Thanks to ANOVA, the assessment of engine health is based on a statistically proven correlation between the values of the dependent variable and the classifying factors.

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 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.

Microturbines can be used not only in models and education but also to propel UAVs. However, their wider adoption is limited by their relatively low efficiency and durability. Validated simulation models are required to monitor their performance, improve their lifetime, and design engine control systems. This study aims at developing a numerical model of a micro gas turbine for prediction and prognostics of engine performance. To build a reliable zero-dimensional model, the available compressor and turbine maps were scaled to the available test bench data with the least squares method, to meet the performance of the engine achieved during bench and flight tests. A steady-state aeroengine model was implemented in GSP and compared with experimental operating points. The selected flight data was then used as input for the transient engine model. The exhaust gas temperature (EGT) and fuel flow were chosen as the two key parameters to validate the model, comparing the numerical predicted values with the experimental ones. The observed difference between the model and the flight data was lower than 3% for both EGT and fuel flow.

Magnetic sensors are widely used in health management systems for turbomachinery, but their applications in the hot zone are limited due to the loss of magnetic properties by permanent magnets with increasing temperature. The paper presents and verifies models and design solutions aimed at improving the performance of an inductive sensor for measuring the motion of rotating objects operating at elevated temperatures (200-1000C), such as compressor and turbine blades. Physical, analog and mathematical models of the interaction of blades with the sensor were developed. A prototype of the sensor was made and its tests were carried out on the RK-4 rotor rig for the speed of 7000 rpm, in which the temperature of the sensor head was gradually increased to 1100C. The sensor signal level was compared to that of an identical sensor operating at room temperature. The heated sensor works continuously producing the output signal whose level does not change significantly. What is more, a set of six probes passed an initial engine test in an SO-3 turbojet. It was confirmed that the proposed design of the inductive sensor is suitable for blade health monitoring of the last stages of compressors, steam turbines as well as previous generation gas turbines operating below 1000C, even without a dedicated cooling system. In real-engine applications, sensor performance will depend on how the sensor is installed and the available heat dissipation capability

Blade Health Monitoring (BHM) is often necessary in power plants and in aviation to prevent excessive blade vibration and cracks. This article proposes a network of blade tip timing sensors operated in a distributed BHM system. A number of cooperating agents is implemented in smart conditioning units which can autonomously operate in an adverse environment and communicate with other nodes via a serial interface. The project uses special versions of reduced instruction set chips that are able to operate near the hot section of the engine. Due to the limited number of types of microprocessors available in the extended temperature range grading, it was necessary to fully utilize the limited hardware resources and implement preemptive multitasking. For this purpose, a custom operating system and communication protocol were designed. The protocol hosts the middle layer which hides the implementation of the distributed system. The presented architecture ensures the sufficient computational capacity in individual nodes of the network operated in adverse conditions. It is scalable and resistant to transmission errors.

Gas Path Analysis and matching turbine engine models to experimental data are inverse problems of mathematical modelling which are characterized by parametric uncertainty. This results from the fact that the number of measured parameters is significantly lower than the number of components’ performance parameters needed to describe the real engine. In these conditions, even small measurement errors can result in a high variation of results, and obtained efficiency, loss factors etc. can appear out of the physical range. The current methods of engine model identification have developed considerably to provide stable, precise and physically adequate solutions. Presented in this work is an estimation method of engine components’ parameters based on multi-criteria identification which provides stable estimations of parameters and their confidence intervals with the known measurement errors. A priori information about the engine, its parameters and performance is used directly in the regularised identification procedure. The mathematical basis for this approach is the fuzzy sets theory. Forming objective functions and scalar convolutions synthesis of these functions is used to estimate gas-path components’ parameters. A comparison of the proposed approach with traditional methods showed that its main advantage is high stability of estimation in the parametric uncertainty conditions. Regularization reduces scattering, excludes incorrect solutions which do not correspond to a priori assumptions, and also helps to implement the Gas Path Analysis at the limited number of measured parameters. The method can be used for matching thermodynamic models to experimental data, Gas Path Analysis and also adapting dynamic models for the needs of the engine control system.

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.

Alternative fuels containing biocomponents produced in various technologies are introduced in aviation to reduce its carbon footprint but there is little data describing their impact on the performance and emissions of engines. The purpose of the work is to compare the performance and gas emissions produced from two different jet engines: the GTM-140 microturbine and the full-size DGEN380 turbofan, powered by blends of Jet A-1 and one of two biocomponents: 1) ATJ and 2) HEFA produced from used cooking oil (UCO) in various concentrations. The acquired data will be used to develop an engine emissivity model to predict gas emissions. Blends of the mineral fuel with synthetic components were prepared in various concentrations, and their physicochemical parameters were examined in the laboratory. Measurements of emissions from both engines were carried out in selected operating points using the Semtech DS gaseous analyzer and the EEPS spectrometer. The impact of tested blends on engine operating parameters is limited, and their use does not carry the risk of a significant decrease in aircraft performance or increase in fuel consumption. Increasing the content of biocomponents causes a noticeable rise in the emission of CO and slight increase for some other gasses (HC and NOx), which should not, however, worsen the working conditions of the ground personnel. This implies that there are no contraindications against using tested blends for fuelling gas-turbine engines.