WP1 - Components design and manufacturing

  • To design components matching mechanical, thermal and aerodynamic performances specifications
  • To generate 3D CAD files to manufacture components: combustor simulator and swirlers, HP NGV, rotor blades and disk, liner, LP duct and vanes
  • To compute preliminary models of the components to predict their behaviour. Indeed, obtaining accurate flow distribution within the combustion chamber is mandatory as this can result in significantly different inlet profiles to the turbine that can change local aerodynamics and heat transfer within the turbine. The performance of the non-reacting simulator will therefore be evaluated
  • To manufacture components of the non-reacting combustor and a HP turbine module that will be integrated together

Task 1.1 - Combustor simulator design (M4-M12) - TM, AVIO, WSK, GDTECH
  • Design the non-reaction combustor simulator so as to get a representative turbine inlet boundary condition (Hot spots, swirls, turbulence, unsteadiness, etc.) by mixing hot and cold air.

 D1.1 - Non-reacting combustor simulator design [KEY Deliverable]: A publishable abstract will be available on the project public web site. This report will detail the design of the non-reaction combustor simulator. The RANS CFD to ensure OTDF compliance with specifications will be illustrated. The CAD files will be delivered to validate the integration before manufacturing. [month 12]


Task 1.2 - Turbine flow paths design (M4-M5) - ITP, RRUK, SN
  • Design the flow paths of the turbine according to the WP3 specifications and the industrial requirements. This design activity includes hub and casing geometries and 2D aero computation (triangulation, Pressure ratio, losses…) specifying the interface BCs. Some partners will provide small contributions to cross-check and review the design according to the original specifications. A Design Review Committee will then validate the conception.

D1.2- Flow paths specifications [KEY Deliverable]: A publishable abstract will be available on the project public web site. This report focus on the flow paths design achieved by ITP, including hub and shroud geometries. The 2D aero computation will detailed so as to specify the interface BCs needed for the HP and LP turbine components design. [month 6]


Task 1.3 - Cooled HP turbine components design (M5-M13) - SN, MTU, RRUK, RRD
  • Perform the aero-mechanical design of the cooled HP turbine components (HP NGV, HP rotor blades and disk, liner) considering the SAS and surrounding environment.

D1.3 - Cooled HP turbine design: This report will collect the geometries done by RRUK (Cooled HP NGV), SN (Un-cooled HP rotor) and RRD (Un-cooled HP disk). The CAD will be delivered to WP3 to validate the integration before manufacturing. [month 13]


Task 1.4 - LP inter-duct design (M5-M13) - AVIO, ITP, VAC
  • Perform the aero-mechanical design of the T-duct including a LP NGV. Use of an aggressive turbine duct with an aerodynamic loaded (turning) structural vane/strut instead of a non-turning structural strut. The structural strut should be of a design to allow an internal load carrying structure and air/oil lines, i.e. quite thick. The “duct-vane” is tested in the DLR rig, with TBD instrumentation. Check numerically the impact of the temperature distortion on the downstream LP turbine, on a design provided by AVIO: “contra-rotating turbine”, which influence the turning required on the LP 1st vane.

D1.4 - LP vane in T-duct design: This report will collect the geometries done by VAC (LP strutted duct) and AVIO (LP turbine). The CAD will be delivered to WP3 to validate the integration before manufacturing. [month 12]


Task 1.5 - Test articles manufacturing (M20-M26) - PROGESA, AVIO, DLR, WSK
The manufacturers will execute all the parts drawings and manufacture the components according to the specifications.

D1.5 - Manufactured components [KEY Deliverable]: A publishable abstract will be available on the project public web site. This report will present the manufacturing of the components to be assembled on the test rig. It will detail materials used (an alloy not on the melting side for a vane application at a maximum inlet temperature up to 800K) as well as manufacturing techniques and the corresponding limitations to the airfoil shapes (wire cutting / milling from full material / rapid proto-typing). [month 26]

 



WP7 ? Dissemination and Exploitation WP3 ? Integration WP1 - Components design and manufacturing
WP2 ? Instrumentation design & manufacturing and rig adaptation WP6 ? Synthesis of experiments and computations
WP8 ? Management of FACTOR Project
WP4 ? Measurement campaign
WP5




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