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http://www.swri.org/4org/d18/mechflu/rotating/rotatingspan/brochures.htm
http://www.swri.org/4org/d18/mechflu/planteng/gtspan/audit.htm
Gas Turbine Technology
Gas turbines are a versatile, cost-effective source of electricity, mechanical power, and
propulsion. Gas turbines continually challenge engineers to design, construct, and
operate reliable and efficient turbines that meet maret needs and respect the
environment. !outhwest "esearch #nstitute $!w"#% wors with users, suppliers, and
manufacturers of gas turbines, providing technical services, e&pertise, and research
facilities to meet the challenge. 'ur broad range of capabilities includes:
(aterials )valuation and *esting
+ailure nalysis
ife (anagement, !tress nalysis, and !tructural nalysis
ondestructive )valuation
+luid ynamics and 0eat *ransfer
!ystem and omponent *esting
Gas *urbine (onitoring
*esting, iagnosis, and !upport
omputer-2ased *raining
rtificial #ntelligence ir 3ollution ontrol
+uels, ubricants, and ombustion *echnology
dvanced (aterials and *echnology
*he !olar gas turbine drives a compressor with spiral-grooved dry gas seprovide circulation in the only world-class gas transmission metering rese
facility in the nited !tates. *he e&haust heat recovery unit of the Gas*echnology #nstitute facility provides hot oil as the heat source for a rapi
response gas temperature control system. *he facility was designed by, aoperated and located at !outhwest "esearch #nstitute.
Materials Evaluation and Testing
http://www.swri.org/4org/d18/mechflu/rotating/rotatingspan/brochures.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gtspan/audit.htmhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Materials%20Evaluation%20and%20Testing%23Materials%20Evaluation%20and%20Testinghttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Failure%20Analysis%23Failure%20Analysishttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Life%20Management,%20Stress%20Analysis,%20and%20Structural%20Analysis%23Life%20Management,%20Stress%20Analysis,%20and%20Structural%20Analysishttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Nondestructive%20Evaluation%23Nondestructive%20Evaluationhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Fluid%20Dynamics%20and%20Heat%20Transfer%23Fluid%20Dynamics%20and%20Heat%20Transferhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#System%20and%20Component%20Testing%23System%20and%20Component%20Testinghttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Gas%20Turbine%20Monitoring%23Gas%20Turbine%20Monitoringhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Testing,%20Diagnosis,%20and%20Support%23Testing,%20Diagnosis,%20and%20Supporthttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Computer-Based%20Training%23Computer-Based%20Traininghttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Artificial%20Intelligence%23Artificial%20Intelligencehttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Air%20Pollution%20Control%23Air%20Pollution%20Controlhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Fuels,%20Lubricants,%20and%20Combustion%20Technology%23Fuels,%20Lubricants,%20and%20Combustion%20Technologyhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Advanced%20Materials%20and%20Technology%23Advanced%20Materials%20and%20Technologyhttp://www.swri.org/4org/d18/mechflu/rotating/rotatingspan/brochures.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gtspan/audit.htmhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Materials%20Evaluation%20and%20Testing%23Materials%20Evaluation%20and%20Testinghttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Failure%20Analysis%23Failure%20Analysishttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Life%20Management,%20Stress%20Analysis,%20and%20Structural%20Analysis%23Life%20Management,%20Stress%20Analysis,%20and%20Structural%20Analysishttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Nondestructive%20Evaluation%23Nondestructive%20Evaluationhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Fluid%20Dynamics%20and%20Heat%20Transfer%23Fluid%20Dynamics%20and%20Heat%20Transferhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#System%20and%20Component%20Testing%23System%20and%20Component%20Testinghttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Gas%20Turbine%20Monitoring%23Gas%20Turbine%20Monitoringhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Testing,%20Diagnosis,%20and%20Support%23Testing,%20Diagnosis,%20and%20Supporthttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Computer-Based%20Training%23Computer-Based%20Traininghttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Artificial%20Intelligence%23Artificial%20Intelligencehttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Air%20Pollution%20Control%23Air%20Pollution%20Controlhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Fuels,%20Lubricants,%20and%20Combustion%20Technology%23Fuels,%20Lubricants,%20and%20Combustion%20Technologyhttp://www.swri.org/3pubs/brochure/d04/turbn/turbn.htm#Advanced%20Materials%20and%20Technology%23Advanced%20Materials%20and%20Technology -
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*he #nstitute5s gas turbine materials technology program spans super-alloys, including
directionally solidified and single crystal alloys, coatings, titanium alloys, composites,
ceramics, intermetallics, and polymers, as well as conventional ferrous and nonferrous
materials. !w"# metallurgical laboratories provide scanning electron microscopy,
transmission electron microscopy, acoustic microscopy, atomic force microscopy,
optical microscopy, scanning uger spectroscopy, energy dispersive spectroscopy, 6-ray diffraction, and specimen preparation facilities.
(echanical testing facilities include servo-hydraulic, servo-electric, creep, and impact
machines, augmented by computeri7ed control and data acuisition. *he #nstitute can
perform the most e&acting high temperature testing, including thermo-mechanical
fatigue, creep crac growth, and effects of aggressive environments. !tandard and
advanced fracture mechanics, fatigue, creep, and impact tests are conducted to !*(
standards over a temperature range from the cryogenic regime to more than 9,
degrees +ahrenheit $1,;
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(etallurgical failure analysis of broen blades to determine cause and
seuence of fracture is supplemented with mechanical analysis todetermine the root cause of failure.
*his crac e&tends from the leading edge to the inside cooling surface a
follows the grain boundaries of the cast nicel-base superalloy. )&aminby optical and scanning electron microscopy showed that cracing was
assisted by environmental attac. nalysis from the )lectric 3ower "ese#nstitute gas turbine life management system, developed by !w"#, show
cracing was due to thermal fatigue caused by e&cessively hard engine
operation.
Life Management, Stress Analysis, and Structural
Analysis
*he #nstitute develops algorithms and computeri7ed programs for life prediction, life
management, and life e&tension of gas turbine engines to increase component usage,
ma&imi7e engine availability, and reduce maintenance costs. =e apply the most current
technology, including finite element and boundary element methods, to the stress
analysis of gas turbine components. *he #nstitute is a pioneer in probabilistic structural
mechanics, which integrates computational mechanics and probabilistic methods to
manage distribution of material properties, dimensions, and loads. omputational
facilities include a central >6 computer, distributed worstations, and access to
"? supercomputers. vailable numerical codes include 2@!, !?!, and
!*".
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ir-cooled gas turbine blades have comple& temperature and stress pro
*emperatures are shown in the upper figure and longitudinal stresses arbelow. *his analysis, performed for the )lectric 3ower "esearch #nstitu
$)3"#%, uses a generali7ed plane strain finite element methodology.
+low diagram shows the tass reuired to develop a life management
system for determining the life of gas turbine components. !w"# isone of the few organi7ations capable of performing each step in the
development of these systems.
3redictions of thermal-mechanical fatigue life of first stage bladfrom the )3"# life management system, developed by !w"#, co
well with field data. "esults are used to determine inspection inand to modify engine operation for longer blade life.
Nondestructive Evaluation
*he #nstitute continues to develop new techniues and improved euipment for
nondestructive evaluation of gas turbines and Aet engines. =e apply acoustic emission,
ultrasonics, eddy current, electric current perturbation, magnetic flu& leaage, and
radiometrics to detect flaws in turbines for power and propulsion. *he #nstitute designs
speciali7ed sensors for difficult geometries or confined spaces and maes full use of
computer-controlled scanning, data acuisition, and display to achieve efficient and
reliable detection and discrimination.
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n eddy current inspection system developed by !w"# uses a ta&is scanner to inspect small blades of space shuttle 3s.
space shuttle 3 blade crac is imaged and measured by an eddy current inspection system developed at !w"#. *wo-dimen
display of the processed eddy current signal is shown at left.
Fluid Dynamics and eat Transfer
+luid dynamics, heat transfer, and fluid-structure interaction are essential disciplines to
the effective design, application, and performance evaluation of gas turbines. *he
#nstitute maintains a variety of commercial and !w"#-developed computational fluid
dynamics codes to meet specific needs. number of flow facilities are used in
conAunction with computational methods to support comprehensive simulation and
understanding of fluid flows and their interactions with structures. +low visuali7ation
techniues enhance this capability. +acilities include:
0igh pressure $B,
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3ressure contours and velocity vectors for flow through first stablades are determined from computational fluid dynamics code
2oundary element codes determine heat transfer coefficients ththen used in thermal and stress analysis of the blades. "esults swere obtained with the +'=-9 computer code modified by
omputational modeling is used to analy7e temperature distribution infuel no77les.
System and !om"onent Testing
'ptimum performance and reliability of gas turbines in aeropropulsion, electrical power
generation, and compressor or pump drives is achieved by careful balancing of
conflicting demands that include low seal leaage without rubs, low weight without
e&cessive vibration, high temperatures with long life, and blades free of vibration over a
range of flow and speed conditions. *he ability to test components and systems is
important to achieving this balance.
!w"# has a variety of vibration, flow, noise, and environmental ualification testing
facilities that are effectively used, often under conditions of realistic pressure, flow,
speed, and si7e, in a variety of applications of critical concern to users and
manufacturers of gas turbines. )nvironmental test facilities investigate the effects of
vibration, shoc, temperature, fire, salt fog, and sand and dust erosion on componentsand systems. #nstitute analytical resources complement test facilities.
Gas Turbine Monitoring
Gas turbines are the power source of choice in many applications for mechanical drive
of machinery and for electrical power generation. =hen aero-derivative or large
industrial gas turbines e&perience mechanical vibration, unsatisfactory performance,
surge, stall, or thermal distortion, there is need for effective remedies applied on-site.
!w"# has developed capabilities for measuring, acuiring, and analy7ing the parameters
critical to defining and correcting such problems. *he #nstitute5s remote data acuisition
optimi7es the testing process that can reuire wees or months to assure coverage of
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varied operating conditions. !w"# provides all euipment needed on-site, with rapid
response, to solve critical availability problems.
n !w"# field measurement team installed a specially designed
instrumentation system on a
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!w"# instructional designers integrate >#F with other advanced technologies to
complete a dynamic informational resource for diagnostic training, visual databases,
post disturbance analysis, and blade inspection. *hese resources can be applied as on-
site training.
Artificial %ntelligence
*he #nstitute applies artificial intelligence techniues to the gas turbine industry.
number of nowledge-based, or e&pert, systems has been developed to support the
maintenance and life assessment of gas turbine engines, including a system used to
recommend protective coatings for gas turbines. nother !w"# system predicts the
remaining life of gas turbine no77le vanes, including estimated crac length, number of
hours remaining, and the number of starts left for the no77le. *hese systems run on 3s
as well as larger computers.
Air &ollution !ontrol
*he many emissions produced by turbines are of great concern environmentally. *he
#nstitute has developed, uantified, and validated procedures to characteri7e and
measure regulated emissions that include '&, !'&, ', 'B, 'B, total hydrocarbons,
particulates, and more than B unregulated emissions. *ypical proAects involve:
ew procedures development
3articulate characteri7ation
)ngine modifications evaluation
+uels and fuel properties evaluation
ompliance testing
)&haust catalyst and particulate trap development and evaluation
urrent emissions control technologies application
'n-site tests of propulsion and stationary turbines are performed conveniently with a
mobile emissions laboratory designed and constructed by !w"# that provides
continuous hydrocarbon, ', '&, 'B, and 'Banalysis, with additional capabilities for
individual hydrocarbon, smoe, and particulate analysis.
Fuels, Lubricants, and !ombustion Technology
*he #nstitute, through fundamental and applied research, sees to better understand how
physical and chemical properties of fuels influence emissions, performance, and
durability of engines and fuel systems. !w"# programs support military and civilian
aviation and have additional applications for marine and stationary gas turbines.
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*his gas turbine combustor facility was developed to study the
of fuel properties on flame radiation, liner temperature, e&haustsmoe, gaseous emissions, cold weather and altitude ignition, a
flame stabili7ation. 3ressure capabilities range from 1/4 to 1;atmospheres at temperatures from -4 degrees to 1,
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erospace
'il, gas, and chemical
(anufacturing and transportation
(edical
=ith 11 technical divisions and hundreds of fully euipped laboratories, !w"# uses amultidisciplinary approach to solve problems for maAor industries and small businesses
alie.
Systematic Failure Analysis
!w"# investigators use systematic failure analysis to help industry and government:
#dentify design and process deficiencies
ower operating costs
#mprove safety "eceive impartial evaluations
)&tend component service life
&o'er Generation
+ossil fuel, nuclear, and combined-cycle power companies use materials and structures
under demanding environmental conditions for long periods of time. s the years of
service increase, the possibility of failure grows.
!w"# has e&tensive e&perience conducting power plant investigations. 3rograms rangefrom identifying the cause of boiler tube, comple& compressor, and turbine component
failures, to investigating radioactive components such as vent lines, pipes, and valves.
*his e&perience and an in-house radioactive materials laboratory mae !w"# a leader in
power industry failure analysis.
#n the #nstitute5s radioactive materials handling
laboratory, failed radioactive components,materials, and euipment are investigated in
accordance with radiation safety standards.
Aeros"ace
#nvestigation of failed, craced, and damaged aerospace structures is crucial to thecontinued safe operation of the nation5s aging fleet of civilian and military aircraft.
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#nstitute staff members are e&perts in identifying fatigue, a maAor failure mechanism in
aircraft materials, and are schooled in manufacturing practices and codes relevant to
military and commercial aircraft. !w"# methods allow early identification of cracing
to provide a greater margin of safety and more accurately predict service life.
#nvestigations have been conducted on commercial and military aircraft, including the
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*he automobile, te&tile, and shipping industries fabricate products using both
conventional and advanced manufacturing technologies. +ailures can occur during
manufacturing or while the product is in service. !w"# has conducted failure
investigations for numerous product support and manufacturing operations, studying a
wide variety of components and euipment, such as springs, pistons, forged parts, and
conveyor systems.
!w"# characteri7ed cracs in the storage tans of
this liuid natural gas taner. fter performinganalyses, the #nstitute recommended repairs to
e&tend the service life of the taner.
#nstitute failure analysts investigate ways to improve product life with the latest
technological developments. )&les include fuels and lubricants research and new
coatings for improved lubrication and reduced wear. !w"# e&perts also refine
fabrication practices, ranging from welding techniues for submersible pressure vessels
to the superplastic forming of parts.
!cientists e&amined this paper mill bearing todetermine if a catastrophic failure was caused by
operating conditions or by a material flaw.
Medical A""lications
dvances in medical euipment and biomedical technology have generated a variety of
uses for common materials and new, biocompatible materials for euipment and
implanted devices. *he comple& interactions of stress, friction, wear, and chemical
attac that occur in the human body can cause material-related failure. #nstitute
researchers investigate failure mechanisms in biomedical implants and medical
euipment, such as wear and delamination in orthopedic service. #n addition, the
material, mechanical, and chemical properties of devices are characteri7ed followinglong-term service.
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*he #nstitute conducts failure analyses of medicaleuipment, such as this catheter wire and needle
used in a radiation therapy device.
Facilities
*he #nstitute5s modern laboratories are euipped to handle all aspects of failure analysis.
#nstrumentation includes:
!canning electron microscopes for fractographic and metallographic analysis
n 6-ray diffraction system for deposit analysis
)nergy-dispersive 6-ray systems to identify aggressive corrosion products
transmission electron microscope for fractographic and microstructural
analysis
scanning auger microprobe to identify surface contaminants and
microstructural phases
!canning tunneling and atomic force microscopes for nanoscale surface
topography
(etallographs for heat treat verification, microstructural e&amination, and
material characteri7ation
photographic laboratory to document investigations
portable microscope and hardness unit for field investigations
!i&teen closed-loop, servo-hydraulically controlled mechanical test systems utoclaves for high-pressure and high-temperature corrosion investigations
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!w"# uses metallographs to determine crac
morphologies, microstructural anomalies, andheat treatments. 0ere, a staff member e&amines
the microstructure of a failed steel Aournal.
scanning electron microscope coupled to
energy-dispersive spectroscopic and imageanalysis systems determines fracture
morphology, microstructural anomalies, and
chemical compositions of failed components.
+acilities and laboratories are augmented by a networ of computeri7ed data acuisition
and analysis euipment and a technical library containing more than 44, boos and
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!w"# analy7es thermal and pressure stresses to
determine what caused failure of a cracedstainless steel isolation valve from a nuclear
power plant.