The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen

Alexander V. Murray; Peter T. Ireland; Nick R. Green; Michael Wickins; Richard Hood; Janendra Telisinghe

doi:10.1115/GT2023-103682

The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen

Alexander V. Murray, Peter T. Ireland, Nick R. Green, Michael Wickins, Richard Hood, Janendra Telisinghe

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

Abstract

With the hot stage of a modern aeroengine operating with combustor firing temperatures well beyond the melting point of the nickel superalloys from which the turbine blades are manufactured, developments to the methods of cooling of these components are required to advance performance. Double-wall, effusion systems exhibit a quasi-transpiration like cooling effect with recent work demonstrating their exceptional cooling performance. Such systems are characterised by two walls, one with impingement holes and the other with film cooling holes, that are mechanically and thermally connected via pedestals. However, manufacturing such geometries from single crystal nickel superalloys remains a significant barrier to entry into service.

This paper presents a method of manufacturing double-wall effusion specimens from a nickel superalloy commonly used in modern commercial high pressure turbine components. The method maintains the mechanical integrity associated with nickel superalloys. Details of the method are presented alongside x-ray and GOM laser scan data of a flat-plate test article that demonstrates the success of the manufacturing process. Aerothermal testing of the specimen in a bespoke recirculating wind-tunnel facility was undertaken in which the overall cooling effectiveness of the system is obtained. The results reaffirm the excellent cooling performance of double-wall, effusion systems and further validate the manufacturing methodology as a method by which to realise enhanced cooling effectiveness in service.

Original language	English
Title of host publication	Turbo Expo: Power for Land, Sea and Air
Subtitle of host publication	Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy
Publisher	American Society of Mechanical Engineers (ASME)
Volume	8
ISBN (Electronic)	9780791887028
DOIs	https://doi.org/10.1115/GT2023-103682
Publication status	Published - 28 Sept 2023
Event	ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023 - Boston, United States Duration: 26 Jun 2023 → 30 Jun 2023

Publication series

Name	Proceedings of the ASME Turbo Expo
Volume	8

Conference

Conference	ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023
Country/Territory	United States
City	Boston
Period	26/06/23 → 30/06/23

Bibliographical note

Funding Information:
The authors would like to express their thanks for the on-going support provided by the EPSRC Transpiration Cooling grant (EP/P000878/1) and by Rolls-Royce plc. The authors

Funding Information:
The authors would like to express their thanks for the ongoing support provided by the EPSRC Transpiration Cooling grant (EP/P000878/1) and by Rolls-Royce plc. The authors would also like to thank the technicians and staff at the High Temperature Research Centre, University of Birmingham and the Oxford Thermofluids Institute, University of Oxford.

Publisher Copyright:
Copyright © 2023 by ASME.

ASJC Scopus subject areas

General Engineering

Access to Document

10.1115/GT2023-103682Licence: None: All rights reserved

Cite this

Murray, A. V., Ireland, P. T., Green, N. R., Wickins, M., Hood, R., & Telisinghe, J. (2023). The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen. In Turbo Expo: Power for Land, Sea and Air: Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy (Vol. 8). Article v008t17a018 (Proceedings of the ASME Turbo Expo; Vol. 8). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/GT2023-103682

Murray, Alexander V. ; Ireland, Peter T. ; Green, Nick R. et al. / The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen. Turbo Expo: Power for Land, Sea and Air: Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy. Vol. 8 American Society of Mechanical Engineers (ASME), 2023. (Proceedings of the ASME Turbo Expo).

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title = "The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen",

abstract = "With the hot stage of a modern aeroengine operating with combustor firing temperatures well beyond the melting point of the nickel superalloys from which the turbine blades are manufactured, developments to the methods of cooling of these components are required to advance performance. Double-wall, effusion systems exhibit a quasi-transpiration like cooling effect with recent work demonstrating their exceptional cooling performance. Such systems are characterised by two walls, one with impingement holes and the other with film cooling holes, that are mechanically and thermally connected via pedestals. However, manufacturing such geometries from single crystal nickel superalloys remains a significant barrier to entry into service.This paper presents a method of manufacturing double-wall effusion specimens from a nickel superalloy commonly used in modern commercial high pressure turbine components. The method maintains the mechanical integrity associated with nickel superalloys. Details of the method are presented alongside x-ray and GOM laser scan data of a flat-plate test article that demonstrates the success of the manufacturing process. Aerothermal testing of the specimen in a bespoke recirculating wind-tunnel facility was undertaken in which the overall cooling effectiveness of the system is obtained. The results reaffirm the excellent cooling performance of double-wall, effusion systems and further validate the manufacturing methodology as a method by which to realise enhanced cooling effectiveness in service.",

author = "Murray, {Alexander V.} and Ireland, {Peter T.} and Green, {Nick R.} and Michael Wickins and Richard Hood and Janendra Telisinghe",

note = "Funding Information: The authors would like to express their thanks for the on-going support provided by the EPSRC Transpiration Cooling grant (EP/P000878/1) and by Rolls-Royce plc. The authors Funding Information: The authors would like to express their thanks for the ongoing support provided by the EPSRC Transpiration Cooling grant (EP/P000878/1) and by Rolls-Royce plc. The authors would also like to thank the technicians and staff at the High Temperature Research Centre, University of Birmingham and the Oxford Thermofluids Institute, University of Oxford. Publisher Copyright: Copyright {\textcopyright} 2023 by ASME.; ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023 ; Conference date: 26-06-2023 Through 30-06-2023",

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Murray, AV, Ireland, PT, Green, NR, Wickins, M, Hood, R & Telisinghe, J 2023, The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen. in Turbo Expo: Power for Land, Sea and Air: Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy. vol. 8, v008t17a018, Proceedings of the ASME Turbo Expo, vol. 8, American Society of Mechanical Engineers (ASME), ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023, Boston, United States, 26/06/23. https://doi.org/10.1115/GT2023-103682

The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen. / Murray, Alexander V.; Ireland, Peter T.; Green, Nick R. et al.
Turbo Expo: Power for Land, Sea and Air: Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy. Vol. 8 American Society of Mechanical Engineers (ASME), 2023. v008t17a018 (Proceedings of the ASME Turbo Expo; Vol. 8).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

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AB - With the hot stage of a modern aeroengine operating with combustor firing temperatures well beyond the melting point of the nickel superalloys from which the turbine blades are manufactured, developments to the methods of cooling of these components are required to advance performance. Double-wall, effusion systems exhibit a quasi-transpiration like cooling effect with recent work demonstrating their exceptional cooling performance. Such systems are characterised by two walls, one with impingement holes and the other with film cooling holes, that are mechanically and thermally connected via pedestals. However, manufacturing such geometries from single crystal nickel superalloys remains a significant barrier to entry into service.This paper presents a method of manufacturing double-wall effusion specimens from a nickel superalloy commonly used in modern commercial high pressure turbine components. The method maintains the mechanical integrity associated with nickel superalloys. Details of the method are presented alongside x-ray and GOM laser scan data of a flat-plate test article that demonstrates the success of the manufacturing process. Aerothermal testing of the specimen in a bespoke recirculating wind-tunnel facility was undertaken in which the overall cooling effectiveness of the system is obtained. The results reaffirm the excellent cooling performance of double-wall, effusion systems and further validate the manufacturing methodology as a method by which to realise enhanced cooling effectiveness in service.

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Murray AV, Ireland PT, Green NR, Wickins M, Hood R, Telisinghe J. The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen. In Turbo Expo: Power for Land, Sea and Air: Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy. Vol. 8. American Society of Mechanical Engineers (ASME). 2023. v008t17a018. (Proceedings of the ASME Turbo Expo). doi: 10.1115/GT2023-103682

The Manufacturing and Experimental Validation of a Nickel Superalloy Double-Wall, Effusion Test Specimen

Abstract

Publication series

Conference

Bibliographical note

ASJC Scopus subject areas

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