There are several challenges for the development of future high-pressure turbines of aircraft engines: Besides a high efficiency, low weight and costs, there are increasing requirements concerning service life and reliability. The development cycles have to be short and steady, and the after-sales support should be effective and cost-efficient.
The objective of the RobusTurb project is to develop several technological aspects which all contribute to the overall target of a robust high-pressure turbine. Therefore, the project focuses on connecting various concepts, forecasts and new alloys and materials.
To capture the multidisciplinary nature of potential challenges, the RobusTurb project is divided into 9 subprojects:
- Subproject 1- Improved aero-thermodynamic concepts
- Subproject 2- “cyclone” cooling concept and model of the turbulent Prandtl number
- Subproject 3- non-stationary impingement cooling concepts
- Subproject 4- energy consumption: Overall performance of the high-pressure turbine
- Subproject 5- draft: transonic turbine with 1.5 levels.
- Subproject 6- multidisciplinary optimization
- Subproject 7- Improved modelling of the contact points
- Subproject 8- Improved assessment of damages
- Subproject 9- Evaluation of the “Allvac 718Plus” material
According to the different subprojects, the following results have been achieved:
- Subproject 1- Improved aero-thermodynamic concepts: They were able to develop an overall aero-thermodynamic model of an aircraft turbine. The significant progress in terms of connection, simulation and optimization of complex structures will have an impact on further research and development activities.
- Subproject 2- “cyclone” cooling concept and model of the turbulent Prandtl number: Successful implementation of experiments on various test benches. A detailed description of the processes inside a “cyclone” cooling cell was created.
- Subproject 3- non-stationary impingement cooling concepts: the project focused on transferring the existing findings into an applicable configuration. Therefore, a special test bench was drafted, built and tested.
- Subproject 4- energy consumption: Overall performance of the high-pressure turbine: The key question was, whether an increased turbine power leads to higher heat losses? This could compensate the hoped-for positive effect of increased power. Therefore, a model was developed, validated and implemented.
- Subproject 5- draft: transonic turbine with 1.5 levels: Thanks to the configuration of the aerodynamic structure of the turbine and tests to find the best composition of the individual components inside the turbine, the efficiency could be increased.
- Subproject 6- multidisciplinary optimization: This subproject is based on previous findings from the project “HDT-Transsonisch: Single stage transonic high pressure turbine”. The interdisciplinary design tool SMART, which has already been implemented successfully, obtained further improvements: An interface between SMART and the Unigraphics (UG) CAD models was created. In a second work package, a new function was implemented in SMART which provides analysis regarding the robustness of a specific design. In the third work package, an automated parameterization was implemented, which contributes to a faster process.
- Subproject 7- Improved modelling of the contact points: aircraft turbines have a complex coupling of blades and rotating disk. At the contact surfaces, rubbing phenomena occur. For a better prognosis, a 3dimensional, rubbing-sensitive contact model was developed with mathematical methods.