Small Scale testing of Nickel-based Superalloys produced by ALM

2021 ◽  
Author(s):  
◽  
Hani Hilal
Keyword(s):  
Gas Turbine ◽  
Process Parameters ◽  
Structural Integrity ◽  
Defect Formation ◽  
Aerospace Industry ◽  
Small Scale ◽  
High Temperature Strength ◽  
Analytical Methodology ◽  
Industrial Sectors ◽  
Wide Range

Nickel-based superalloys exhibit an impressive range of mechanical properties, from high temperature strength and toughness to excellent oxidation and corrosion resistance. It is for these reasons that they are heavily incorporated in a wide range of industrial sectors, particularly the aerospace industry where they are extensively utilised within the combustor and turbine section of a holistic gas turbine engine, where temperatures often reach arduous conditions. Although nickel-based superalloys are typically manufactured using traditional cast and wrought methodologies, the aerospace industry is becoming increasingly interested in the use of alternative manufacturing methods in an attempt to further drive gas turbine development through weight reduction and increased Turbine Entry Temperatures (TET). As such, interest regarding the use of near-net shape manufacturing technologies such as Additive Layer Manufacturing (ALM) has risen in parallel, but concerns have arisen given the metallurgical complexity of the process and the prevalence of phenomena such as anisotropic behaviour, residual stressing and structural integrity. This thesis has investigated the influence of key process parameters and variables on the mechanical and microstructural behaviour of the two-contrasting nickel-based superalloys, CM247LC and IN718. A novel miniaturised mechanical testing method, Small Punch (SP), in combination with in-depth material characterisation techniques was implemented on a series of Laser Powder Bed Fusion (LPBF) variants of differing build orientation and parameter selections. In addition to this, a robust analytical methodology was employed on a series of LPBF variants in order to ascertain process parameters’ influence on melt pool profile and both alloys relative propensity for defect formation. The findings of this work will help further the understanding of parameter selection and support a key development strategy being implemented by Rolls-Royce plc. regarding the safe incorporation of additive components into service.

Parametric Analysis of Small Scale Recuperated SOFC/Gas Turbine Cycles

2004 ◽  
Author(s):  
Stefano Campanari
Keyword(s):  
Gas Turbine ◽  
Small Scale ◽  
Quality Level ◽  
Performance Potential ◽  
Sensitivity Assessment ◽  
Wide Range ◽  
Real Performance ◽  
Combined Cycles ◽  
Gas Turbine Power Plant ◽  
Cycle Efficiency

High temperature fuel cells are experiencing an increasing amount of attention thanks to the operation of several prototype plants, including an integrated Solid Oxide Fuel Cell (SOFC) and gas turbine power plant. Several authors estimate that the projected performances of such cycle have the potential of exceeding those of combined cycles, even at a small-scale size and with an extremely low environmental impact. However, performance estimates generally cover a very wide range, with predicted net electric efficiency spanning between 55 and 70%. The reasons for this excessive variety of results is generally hidden into the different quality assumptions which are made for the simulation of cycle components, as well as in the different level of detail considered for the design of the cycle layout. Starting with the detailed analysis of a 55% efficient plant layout proposed by a manufacturer, this paper investigates the effects of the most significant component quality features (efficiencies, losses) on small scale recuperated SOFC hybrid cycles performances, by mean of a sensitivity assessment. The work provides a comprehensive list of cycle components performance assumptions, frequently lacking in the available literature, easily allowing a future comparison with the work of other researchers. The aim of the work is to better focus the real performance potential of such cycles and to evidence the way to achieve the highest projected efficiencies; as a result of the simulations performed, two “advanced scenario” plant configurations are presented and discussed, based also on a second law analysis. The analysis includes a discussion of the effects of different pressure ratios on cycle optimization. Results show the possibility of exceeding 65% (LHV) cycle efficiency, depending on the quality level of cycle components.

scholarly journals Investigating the Influence of Process Parameters on the Structural Integrity of an Additively Manufactured Nickel-Based Superalloy

Metals ◽  
2019 ◽  
Vol 9 (11) ◽  
pp. 1191
Author(s):  
Hani Hilal ◽  
Robert Lancaster ◽  
Dave Stapleton ◽  
Gavin Baxter
Keyword(s):  
Structural Integrity ◽  
Influence Of Process Parameters ◽  
Nickel Based Superalloy ◽  
Industrial Sectors ◽  
Heat Treated ◽  
Wide Range ◽  
Heat Treated Condition ◽  
Near Net Shape ◽  
Semi Empirical ◽  
The Impact

Additive manufacturing (AM) is a novel near net shape manufacturing technology that joins metallic powders layer upon layer in conjunction with 3D model data and as such offers tremendous potential to a wide range of industrial sectors given its ability to produce highly intricate components with very little material wastage. Subsequently, the aerospace industry has become particularly interested in utilising AM as a means of manufacturing nickel-based superalloys for high-temperature applications, such as non-rotating components within gas turbine engines, which are traditionally fabricated through traditional cast and wrought methodologies. As a result of this, a detailed understanding of the influence of key process variables on the structural integrity of the different experimental builds is required. A semi-empirical quantitative approach for melt track analysis has been conducted and the impact on melt track sizing and defect forming mechanisms in the as-built and heat-treated condition is investigated.

scholarly journals Thermal Optimisation of Longitudinal Ribs in Variable Geometry Ducts

1997 ◽  
Author(s):  
S. Naik ◽  
S. D. Probert
Keyword(s):  
Heat Transfer ◽  
Gas Turbine ◽  
Structural Integrity ◽  
Turbine Blades ◽  
Variable Geometry ◽  
Maximum Heat ◽  
Operational Conditions ◽  
Longitudinal Ribs ◽  
Maximum Heat Transfer ◽  
Wide Range

Augmenting the heat transfer rates in the internal flow passages of several components of a gas turbine, such as the turbine blades, vanes and combustor walls is an important pre-requisite for maintaining their structural integrity. This is particularly paramount when higher turbine inlet temperatures and pressure ratios are utilised for enhancing the thermal efficiencies of the gas turbine plant. In this study, the heat transfer enhancement, which can be achieved by longitudinal ribs in a variable geometry duct, has been examined. With the base of the ribs maintained at a constant temperature, it was observed that the optimal rib spacing, which corresponded to the maximum heat transfer from the ribs, was a strong function of the rib height to length ratio and the Reynolds number but relatively insensitive to the amount of clearance above the ribs. A design correlation is proposed which shows the distribution of this optimal rib spacing for a wide range of rib geometrical and operational conditions. Comparisons of the longitudinal ribs with pin fin arrays indicated that at rib height to length ratios of ≥ 0.24, higher heat transfers can be achieved with the longitudinal ribs. The frictional characteristics of the longitudinal ribs is comparable to those of circular pin fins. Measurements of the local heat transfer coefficient for the rib surfaces indicate that it is highly non-uniform along the rib height and length and also significantly influenced by the amount of clearance above the ribs. For all the cases examined, it was observed that developing flow conditions (thermally and hydrodynamically) were prevalent within the longitudinal rib channels.

Application of TEM to Deformation, Wear, and Fracture of Ceramics

1974 ◽  
Vol 32 ◽  
pp. 472-473
Author(s):  
B. J. Hockey
Keyword(s):  
Wear Resistance ◽  
High Temperature ◽  
Mechanical Behavior ◽  
Brittle Materials ◽  
High Temperature Strength ◽  
Wide Range ◽  
Corrosive Environments ◽  
Further Development

Ceramics, such as Al2O3 and SiC have numerous current and potential uses in applications where high temperature strength, hardness, and wear resistance are required often in corrosive environments. These materials are, however, highly anisotropic and brittle, so that their mechanical behavior is often unpredictable. The further development of these materials will require a better understanding of the basic mechanisms controlling deformation, wear, and fracture.The purpose of this talk is to describe applications of TEM to the study of the deformation, wear, and fracture of Al2O3. Similar studies are currently being conducted on SiC and the techniques involved should be applicable to a wide range of hard, brittle materials.

Integrated Design and Multi-Objective Optimization of a Single Stage Heat-Pump Turbocompressor

2013 ◽  
Author(s):  
J. Schiffmann
Keyword(s):  
Design Optimization ◽  
High Efficiency ◽  
Integrated Design ◽  
Heat Pumps ◽  
Small Scale ◽  
Multi Objective Optimization ◽  
Design Constraints ◽  
Multi Objective ◽  
Wide Range ◽  
Standard Design

Small scale turbomachines in domestic heat pumps reach high efficiency and provide oil-free solutions which improve heat-exchanger performance and offer major advantages in the design of advanced thermodynamic cycles. An appropriate turbocompressor for domestic air based heat pumps requires the ability to operate on a wide range of inlet pressure, pressure ratios and mass flows, confronting the designer with the necessity to compromise between range and efficiency. Further the design of small-scale direct driven turbomachines is a complex and interdisciplinary task. Textbook design procedures propose to split such systems into subcomponents and to design and optimize each element individually. This common procedure, however, tends to neglect the interactions between the different components leading to suboptimal solutions. The authors propose an approach based on the integrated philosophy for designing and optimizing gas bearing supported, direct driven turbocompressors for applications with challenging requirements with regards to operation range and efficiency. Using previously validated reduced order models for the different components an integrated model of the compressor is implemented and the optimum system found via multi-objective optimization. It is shown that compared to standard design procedure the integrated approach yields an increase of the seasonal compressor efficiency of more than 12 points. Further a design optimization based sensitivity analysis allows to investigate the influence of design constraints determined prior to optimization such as impeller surface roughness, rotor material and impeller force. A relaxation of these constrains yields additional room for improvement. Reduced impeller force improves efficiency due to a smaller thrust bearing mainly, whereas a lighter rotor material improves rotordynamic performance. A hydraulically smoother impeller surface improves the overall efficiency considerably by reducing aerodynamic losses. A combination of the relaxation of the 3 design constraints yields an additional improvement of 6 points compared to the original optimization process. The integrated design and optimization procedure implemented in the case of a complex design problem thus clearly shows its advantages compared to traditional design methods by allowing a truly exhaustive search for optimum solutions throughout the complete design space. It can be used for both design optimization and for design analysis.

scholarly journals Recent Advances in Enzymatic and Non-Enzymatic Electrochemical Glucose Sensing

Sensors ◽  
2021 ◽  
Vol 21 (14) ◽  
pp. 4672
Author(s):  
Mohamed H. Hassan ◽  
Cian Vyas ◽  
Bruce Grieve ◽  
Paulo Bartolo
Keyword(s):  
Noble Metals ◽  
Direct Electrochemistry ◽  
Glucose Sensing ◽  
Glucose Sensors ◽  
Diabetic Patients ◽  
Past Century ◽  
Industrial Sectors ◽  
Recent Advances ◽  
Wide Range ◽  
Sensitivity And Selectivity

The detection of glucose is crucial in the management of diabetes and other medical conditions but also crucial in a wide range of industries such as food and beverages. The development of glucose sensors in the past century has allowed diabetic patients to effectively manage their disease and has saved lives. First-generation glucose sensors have considerable limitations in sensitivity and selectivity which has spurred the development of more advanced approaches for both the medical and industrial sectors. The wide range of application areas has resulted in a range of materials and fabrication techniques to produce novel glucose sensors that have higher sensitivity and selectivity, lower cost, and are simpler to use. A major focus has been on the development of enzymatic electrochemical sensors, typically using glucose oxidase. However, non-enzymatic approaches using direct electrochemistry of glucose on noble metals are now a viable approach in glucose biosensor design. This review discusses the mechanisms of electrochemical glucose sensing with a focus on the different generations of enzymatic-based sensors, their recent advances, and provides an overview of the next generation of non-enzymatic sensors. Advancements in manufacturing techniques and materials are key in propelling the field of glucose sensing, however, significant limitations remain which are highlighted in this review and requires addressing to obtain a more stable, sensitive, selective, cost efficient, and real-time glucose sensor.

scholarly journals UV Nanoimprint Lithography: Geometrical Impact on Filling Properties of Nanoscale Patterns

Nanomaterials ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 822
Author(s):  
Christine Thanner ◽  
Martin Eibelhuber
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Nanoimprint Lithography ◽  
Failure Modes ◽  
Production Method ◽  
Efficient Production ◽  
Comprehensive Overview ◽  
Replication Method ◽  
Wide Range ◽  
Pattern Size

Ultraviolet (UV) Nanoimprint Lithography (NIL) is a replication method that is well known for its capability to address a wide range of pattern sizes and shapes. It has proven to be an efficient production method for patterning resist layers with features ranging from a few hundred micrometers and down to the nanometer range. Best results can be achieved if the fundamental behavior of the imprint resist and the pattern filling are considered by the equipment and process parameters. In particular, the material properties and pattern size and shape play a crucial role. For capillary force-driven filling behavior it is important to understand the influencing parameters and respective failure modes in order to optimize the processes for reliable full wafer manufacturing. In this work, the nanoimprint results obtained for different pattern geometries are compared with respect to pattern quality and residual layer thickness: The comprehensive overview of the relevant process parameters is helpful for setting up NIL processes for different nanostructures with minimum layer thickness.

scholarly journals Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1157
Author(s):  
Danka Labus Zlatanovic ◽  
Sebastian Balos ◽  
Jean Pierre Bergmann ◽  
Stefan Rasche ◽  
Milan Pecanac ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Spot Welding ◽  
Minimum Energy ◽  
Tool Geometry ◽  
Friction Stir ◽  
Minimum Energy Consumption ◽  
Punch Test ◽  
Wide Range ◽  
Lap Welding

Friction stir spot welding is an emerging spot-welding technology that offers opportunities for joining a wide range of materials with minimum energy consumption. To increase productivity, the present work addresses production challenges and aims to find solutions for the lap-welding of multiple ultrathin sheets with maximum productivity. Two convex tools with different edge radii were used to weld four ultrathin sheets of AA5754-H111 alloy each with 0.3 mm thickness. To understand the influence of tool geometries and process parameters, coefficient of friction (CoF), microstructure and mechanical properties obtained with the Vickers microhardness test and the small punch test were analysed. A scanning acoustic microscope was used to assess weld quality. It was found that the increase of tool radius from 15 to 22.5 mm reduced the dwell time by a factor of three. Samples welded with a specific tool were seen to have no delamination and improved mechanical properties due to longer stirring time. The rotational speed was found to be the most influential parameter in governing the weld shape, CoF, microstructure, microhardness and weld efficiency. Low rotational speeds caused a 14.4% and 12.8% improvement in joint efficiency compared to high rotational speeds for both tools used in this investigation.

scholarly journals A broadbanded pressure differential wave energy converter based on dielectric elastomer generators

2021 ◽  
Author(s):  
Michele Righi ◽  
Giacomo Moretti ◽  
David Forehand ◽  
Lorenzo Agostini ◽  
Rocco Vertechy ◽  
...  
Keyword(s):  
Wave Energy ◽  
Large Deformations ◽  
Dielectric Elastomer ◽  
Wave Energy Converter ◽  
Pressure Differential ◽  
Design Stage ◽  
Small Scale ◽  
Energy Converter ◽  
Wide Range ◽  
The Waves

AbstractDielectric elastomer generators (DEGs) are a promising option for the implementation of affordable and reliable sea wave energy converters (WECs), as they show considerable promise in replacing expensive and inefficient power take-off systems with cheap direct-drive generators. This paper introduces a concept of a pressure differential wave energy converter, equipped with a DEG power take-off operating in direct contact with sea water. The device consists of a closed submerged air chamber, with a fluid-directing duct and a deformable DEG power take-off mounted on its top surface. The DEG is cyclically deformed by wave-induced pressure, thus acting both as the power take-off and as a deformable interface with the waves. This layout allows the partial balancing of the stiffness due to the DEG’s elasticity with the negative hydrostatic stiffness contribution associated with the displacement of the water column on top of the DEG. This feature makes it possible to design devices in which the DEG exhibits large deformations over a wide range of excitation frequencies, potentially achieving large power capture in a wide range of sea states. We propose a modelling approach for the system that relies on potential-flow theory and electroelasticity theory. This model makes it possible to predict the system dynamic response in different operational conditions and it is computationally efficient to perform iterative and repeated simulations, which are required at the design stage of a new WEC. We performed tests on a small-scale prototype in a wave tank with the aim of investigating the fluid–structure interaction between the DEG membrane and the waves in dynamical conditions and validating the numerical model. The experimental results proved that the device exhibits large deformations of the DEG power take-off over a broad range of monochromatic and panchromatic sea states. The proposed model demonstrates good agreement with the experimental data, hence proving its suitability and effectiveness as a design and prediction tool.

scholarly journals A Threat of Farmers’ Suicide and the Opportunity in Organic Farming for Sustainable Agricultural Development in India

2019 ◽  
Vol 11 (8) ◽  
pp. 2400 ◽  
Author(s):  
Karthikeyan Mariappan ◽  
Deyi Zhou
Keyword(s):  
Organic Farming ◽  
Tamil Nadu ◽  
Agricultural Development ◽  
Small Scale ◽  
Conventional Farming ◽  
Wide Range ◽  
Significant Difference ◽  
Small Scale Farmers ◽  
The Cost ◽  
Input Cost

Agriculture is the main sources of income for humans. Likewise, agriculture is the backbone of the Indian economy. In India, Tamil Nadu regional state has a wide range of possibilities to produce all varieties of organic products due to its diverse agro-climatic condition. This research aimed to identify the economics and efficiency of organic farming, and the possibilities to reduce farmers’ suicides in the Tamil Nadu region through the organic agriculture concept. The emphasis was on farmers, producers, researchers, and marketers entering the sustainable economy through organic farming by reducing input cost and high profit in cultivation. A survey was conducted to gather data. One way analysis of variance (ANOVA) has been used to test the hypothesis regards the cost and profit of rice production. The results showed that there was a significant difference in profitability between organic and conventional farming methods. It is very transparent that organic farming is the leading concept of sustainable agricultural development with better organic manures that can improve soil fertility, better yield, less input cost and better return than conventional farming. The study suggests that by reducing the cost of cultivation and get a marginal return through organic farming method to poor and small scale farmers will reduce socio-economic problems such as farmers’ suicides in the future of Indian agriculture.

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